Fuel Tank Painting Preparation Guide
Proper preparation ensures adhesion, prevents corrosion, and extends the tank's lifespan
Safety Precautions
First, safety measures must be prioritized. Empty the tank completely and purge residual fuel vapors using inert gases like nitrogen or through thorough ventilation.
- Complete tank evacuation and vapor purging
- Atmospheric testing with calibrated gas detector
- Full PPE including respiratory protection
- Establish work zone with proper signage
Surface Cleaning
Next, surface cleaning is essential. Remove all contaminants, including dirt, grease, oil, and old paint.
Pressure Washing
Use a high-pressure water jet (2,000–3,000 psi) to blast away loose debris and contaminants
Degreasing
Apply trisodium phosphate or equivalent degreaser for stubborn grease removal
Drying
Allow complete drying - moisture causes paint bubbling and peeling
- Remove all visible contaminants and loose material
- Use appropriate cleaning agents for specific contaminants
- Verify surface is completely dry before proceeding
Rust & Corrosion Treatment
Rust and corrosion treatment follows cleaning to ensure proper paint adhesion.
- Use wire brush, sandblaster, or abrasive pads for rust removal
- Apply phosphoric acid rust converter for pitted areas
- Achieve surface profile of 1.5-3 mils for best results
- Remove all dust and debris after abrasion
Final Surface Preparation
Final inspection and preparation ensures the surface is ready for painting.
- Fill small cracks/dents with metal-compatible filler
- Sand smooth and remove all dust
- Wipe with lint-free cloth and mineral spirits
- Verify surface temperature (50–90°F / 10–32°C)
- Check humidity is below 85%