Rajan Wilcox
Aluminum and polyethylene are two of the four main materials used for fixed sailboat fuel tanks. They each have their own advantages and disadvantages. For example, aluminum tanks are more versatile and resistant to damage and leaks, but they are also more expensive and susceptible to corrosion. On the other hand, polyethylene tanks are more durable, cost-effective, and resistant to corrosion, but they may release vapors over time, causing a fuel smell. Ultimately, the choice between aluminum and polyethylene for a fixed sailboat fuel tank depends on specific requirements, such as cost, durability, and customizability.
| Characteristics | Values |
|---|---|
| Corrosion | Aluminum tanks are prone to corrosion if electrolysis is present. |
| Polyethylene tanks are not susceptible to corrosion. | |
| Durability | Aluminum tanks are more resistant to damage and leaks. |
| Polyethylene tanks are "incredibly durable" and more reliable for gasoline. | |
| Polyethylene tanks have stronger seams than aluminum. | |
| Polyethylene tanks are 20-30% lighter than aluminum tanks of equivalent size. | |
| Customization | Aluminum tanks are more customizable and can be bent into different shapes. |
| Aluminum tanks can be welded and customized as needed. | |
| Polyethylene tanks are available in standard and custom variants. | |
| Polyethylene tanks have limited selection due to most being roto-spun in a mold. | |
| Cost | Polyethylene tanks are cheaper than aluminum tanks. |
| Condensation | Aluminum tanks are more prone to producing condensation. |
| Vapors | Polyethylene tanks can release vapors and cause a fuel smell. |
| Polyethylene tanks can build a static electricity charge during fueling. | |
| Fire | Aluminum tanks are not the best option in case of a fire as they conduct heat and can cause an explosion. |
| Polyethylene tanks are heat insulators and provide more time in case of a fire. |
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What You'll Learn
Aluminium tanks are more versatile and customisable
Aluminium is also far more resistant to damage and leaks than polyethylene. While plastic tanks are incredibly durable, they are susceptible to permeating undesirable tastes and smells. This can be a particular problem with polyethylene tanks on boats with cabins, as the smell of fuel can linger during the summer months.
Another benefit of aluminium tanks is that they are highly resistant to corrosion from salt water or industrial contaminants. However, it is important to minimise the risk of crevice corrosion, which occurs when water gets trapped between the tank and another surface, such as the tank's supporting structure. This can be achieved through careful installation and design.
In terms of weight, HDPE tanks are around 20%-30% lighter than aluminium tanks of equivalent size. This can be an important consideration for boats where weight is a significant factor.
While plastic tanks have their advantages, aluminium tanks offer greater versatility, customisability, and resistance to damage and leaks. They are a good choice for those seeking a bespoke solution for their sailboat fuel tank.
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Polyethylene tanks are more durable and cost-effective
Polyethylene fixed sailboat fuel tanks are a more durable and cost-effective option than aluminium tanks. They are also a safer choice.
Firstly, polyethylene tanks are incredibly durable and long-lasting. They are not susceptible to corrosion, unlike aluminium tanks, which can corrode severely if electrolysis is present and can develop cracks. This was the experience of one sailboat owner, who had to pay $3000 to repair their busted aluminium tank. Another owner reports that their aluminium tank had to be replaced every 10 years due to corrosion, whereas their polyethylene tank has lasted 20 years and is still going strong. Polyethylene tanks also have stronger seams than aluminium, making them safer in the event of an impact.
Secondly, polyethylene tanks are a more cost-effective option. Plastic marine fuel tanks generally cost less than aluminium tanks. They are also a more reliable option, as they are not affected by ethanol and do not produce condensation. This is an important consideration, as condensation can lead to water becoming trapped between the tank and another surface, causing crevice corrosion in aluminium tanks.
Thirdly, polyethylene tanks are a safer choice. Plastic acts as a heat insulator, whereas metal conducts heat. Therefore, in the event of a fire, the risk of exploding diesel fuel is a very real and dangerous possibility with aluminium tanks.
However, it is important to note that polyethylene tanks do have some drawbacks. They tend to build up a static electricity charge very quickly while fuelling, so it is important to ground the tank and pump during this process. They are also more limited in their selection, as most plastic tanks are roto-spun in a mould, making custom tanks expensive.
Overall, polyethylene fixed sailboat fuel tanks are a more durable and cost-effective option than aluminium tanks, with the added benefit of enhanced safety features.
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Aluminium tanks are more resistant to damage and leaks
Polyethylene tanks are prone to permeating fuel vapours through the plastic over time, which can result in a strong fuel smell, especially in the heat of the summer. This can be a significant issue for boats with cabins. Additionally, polyethylene tanks are more likely to develop crevice corrosion, which occurs when water gets trapped between the tank and another surface, such as the tank supporting structure. This corrosion is due to the aluminium surface being starved of oxygen.
Furthermore, aluminium tanks offer the advantage of welding fittings directly onto the tank, providing customisation options not available with plastic tanks, which require metal fixings to be screwed in. Aluminium fabrication shops are widespread, making it convenient to find a manufacturer for custom aluminium tanks.
While polyethylene tanks are known for their durability, they are not as resistant to damage and leaks as aluminium tanks. Aluminium's higher resistance to leaks is a crucial advantage, especially in the context of fixed sailboat fuel tanks, where the tank's integrity is essential to prevent fuel spills and potential environmental damage.
In summary, while both materials have their advantages and disadvantages, aluminium tanks offer superior resistance to damage and leaks, making them a more reliable choice for fixed sailboat fuel tanks.
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Polyethylene tanks are not susceptible to corrosion
Polyethylene fixed sailboat fuel tanks are not susceptible to corrosion, unlike aluminum tanks, which can corrode severely if electrolysis is present. This makes polyethylene a more durable option for fuel tanks, as it is also resistant to salt water and industrial contaminants.
Polyethylene is a plastic that is often used as an alternative to aluminum in the creation of fuel tanks for boats and planes. One of the key advantages of polyethylene is that it is not susceptible to corrosion. This is because it is a non-metallic composite material, so it does not have any metal components that can corrode over time. In comparison, aluminum tanks are prone to corrosion, especially in the presence of electrolysis, which can lead to cracks in the tank and costly repairs.
The durability of polyethylene tanks is further enhanced by their resistance to salt water and industrial contaminants. This makes them a good choice for boats that are exposed to saltwater environments or industrial chemicals. Additionally, polyethylene tanks are known for their strong seams, which contribute to their overall durability.
While polyethylene tanks offer superior corrosion resistance, they are not without their drawbacks. One consideration is that polyethylene tanks tend to build up static electricity during fueling, so proper grounding is essential. Another potential issue is the release of vapors through the plastic over time, which can result in a fuel smell in the boat. However, it is worth noting that approved polyethylene tank materials are vapor-resistant and not more permeable to fuels than iron.
In summary, polyethylene fixed sailboat fuel tanks offer the advantage of being corrosion-resistant, durable, and resistant to salt water and industrial contaminants. However, it is important to be mindful of the potential for static electricity buildup and vapor release, which can be mitigated through proper grounding and the use of approved tank materials.
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Aluminium tanks are more prone to condensation
Aluminium and polyethylene are two of the four main materials used for marine fuel tanks. Aluminium tanks are more prone to producing condensation than polyethylene tanks. This is because aluminium is a metal that conducts heat, and therefore has the risk of causing diesel fuel to explode.
In an aeroplane, it is easy to drain the water out of an aluminium tank before flying. However, this would be harder to design in a boat. Polyethylene tanks, on the other hand, do not have this issue, as they are made from plastic, which is a heat insulator. While plastic tanks can also melt in a fire, they are less likely to cause the fuel to explode.
Aluminium tanks are also more susceptible to crevice corrosion, which occurs when water gets trapped between the tank and another surface, such as the tank supporting structure. This is because the water is trapped in a crevice, and the aluminium surface is starved of oxygen, leaving it open to corrosion. Polyethylene tanks are not affected by corrosion, as they are made from plastic, which is not susceptible to corrosion.
Another advantage of polyethylene tanks is that they are stronger than aluminium tanks. This is because aluminium seams are weaker than polyethylene seams, and are more likely to split and haemorrhage fuel in the event of an impact. Polyethylene tanks are also lighter than aluminium tanks, which can be beneficial on a boat where weight is a concern.
Overall, while both aluminium and polyethylene tanks have their advantages, polyethylene tanks may be preferable for boats due to their lower susceptibility to condensation and corrosion, as well as their stronger seams and lighter weight.
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Frequently asked questions
Polyethylene fixed sailboat fuel tanks have many advantages over aluminum tanks. They are not susceptible to corrosion, they are more durable, cost-effective, and reliable. They are also not affected by ethanol.
Polyethylene fixed sailboat fuel tanks can permeate vapours through the plastic over time, leading to a faint gas smell. They also tend to build up static electricity charges very quickly while fuelling, which can be dangerous.
Aluminum fixed sailboat fuel tanks are more prone to producing condensation than polyethylene tanks. They can also corrode severely if electrolysis is present and develop cracks in boats that are run hard. In the event of a fire, aluminum tanks pose a risk of exploding diesel fuel as metal conducts heat.
