What are gas station tanks made of?
Gas station tanks are typically carbon steel with protective coatings and corrosion-control systems, though fiberglass-reinforced plastic (FRP) and high-density polyethylene (HDPE) tanks are also common alternatives. Many modern designs use double-wall construction or composite materials to strengthen containment and meet environmental safeguards.
In practice, underground storage tanks (USTs) at filling stations are usually steel shells with protective coatings, cathodic protection, and leak-detection systems, or FRP tanks that resist corrosion without metal. Plastic tanks offer corrosion resistance in challenging soil conditions. Regulators require secondary containment and leak detection for new tanks, shaping material choices and design features.
Materials used in gas station tanks
The following are the main materials you’re likely to encounter at today's stations, along with a short note on where they’re used and why they're chosen.
- Carbon steel with corrosion protection — The traditional choice for underground storage tanks. These tanks are coated internally or with epoxy/urethane linings and often paired with cathodic protection (sacrificial anodes or impressed current) and, in many cases, a secondary containment space to detect leaks.
- Fiberglass-reinforced plastic (FRP) tanks — Nonmetallic, highly resistant to rust and chemical attack, FRP tanks are used in both underground and above-ground settings where soil chemistry or maintenance concerns favor a plastic shell. They typically require different leak-detection approaches.
- High-density polyethylene (HDPE) and other plastics — Monolithic plastic tanks that resist corrosion and are easier to install in difficult soils. Used for underground storage in some regions; performance depends on temperature and compatibility with fuel blends.
- Composite or double-wall systems — These tanks pair a primary inner container with an outer shell to provide secondary containment. They can be steel, FRP, or plastic in the outer layer and are common where regulators require an extra leak barrier.
- Concrete tanks — Once more common in older stations, now relatively rare for gasoline storage due to concerns about cracking and groundwater infiltration, but still found in some legacy or specialty installations.
- Above-ground storage tanks (ASTs) — For certain applications (including some fleet or backup-storage sites), ASTs are typically steel or aluminum and follow the same coating and leak-prevention principles as underground units.
Regulatory standards and site conditions heavily influence material choice. Steel offers strength and long service life when protected, while plastics reduce corrosion risk but may impose weight or temperature considerations. Secondary containment and leak-detection systems remain central to tank design and operation.
Summary
Gas station tanks are most commonly steel with corrosion protection, or nonmetallic options like FRP and HDPE, with many systems using double-wall or composite configurations to provide secondary containment. The exact material depends on soil conditions, regulatory requirements, product compatibility, and cost, but safety and leak-prevention remain the guiding priorities.
How much does a fiberglass fuel tank cost for a gas station?
The average cost of a double-walled, 12,000-gallon fiberglass fuel tank for gas stations is $ 25,000 to $ 30,000. It's important to work with an experienced fuel tank installation contractor to gain the benefit of proven, comprehensive support.
What are gas station gas tanks made of?
The most common materials for fuel tanks are metal or plastic. Metal (steel or aluminium) fuel tanks are usually built by welding stamped sheetmetal parts together. Plastic fuel tanks usually built using blow molding, which allows more complex shapes to be used.
Is HDPE ok for gasoline?
Yes, high-density polyethylene (HDPE) can hold gasoline, as it is the standard material for modern plastic gas cans and car fuel tanks. While some sources caution against long-term storage in general-purpose plastic drums due to potential degradation, specifically designed HDPE containers are made to be resistant and durable enough for fuel storage.
HDPE and gasoline
- Chemical resistance: HDPE is a non-polar plastic that is resistant to organic solvents like gasoline, meaning it won't dissolve or significantly degrade on contact.
- Standard material: It is the material of choice for portable gas cans because it is lightweight and corrosion-resistant. Many modern car fuel tanks are also made from HDPE.
- Safety features: Approved, modern HDPE gas cans are manufactured to specific safety standards. This includes being thick enough to withstand wear and tear and being designed with features like flame arrestors and pressure relief vents to prevent ignition and vapor escape.
Important considerations
- Long-term vs. short-term storage: While HDPE is resistant, storing gasoline in general-purpose HDPE containers for long periods is not recommended by some experts. Prolonged exposure can cause permeation and eventual breakdown, which is a risk for general plastic drums.
- Designed for purpose: It's crucial to use a container specifically manufactured and approved for gasoline storage. A standard HDPE container is not the same as a purpose-built, safety-certified gas can.
- Modern tanks: Modern automotive fuel tanks are often multilayered, using materials like HDPE with a barrier layer (such as EVOH) to prevent gasoline vapors from permeating through the plastic into the atmosphere.
How long will an aluminum fuel tank last?
While composite (fiberglass and resin) tanks require little or no attention, an aluminum or steel tank can fail (start to leak) in less than five years. In most cases, once a fuel tank starts to leak, it must be replaced.
