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In 2024, a large automotive components manufacturer in Southeast Asia faced escalating maintenance costs on its carbon steel cooling tanks due to corrosion and scaling.
Frequent downtime caused energy inefficiency and chemical contamination in the cooling circuit.
The engineering team sought a non-corrosive, lightweight, and thermally stable alternative — leading to the selection of industrial FRP tanks supplied by GTOFRP.
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| Parameter | Specification |
|---|---|
| Cooling Tower Capacity | 300 m³/hr |
| Operating Temperature | 5–40°C |
| pH Range | 6.5–8.5 |
| Chemical Resistance | Sodium hypochlorite & cooling additives |
| Structural Design | Cylindrical vertical FRP tank (filament-wound) |
| Standards | ASTM D3299, BS EN 13121 |
The tanks were designed for continuous industrial operation, combining filament-wound fiberglass layers and UV-resistant resins for outdoor exposure.
Fiberglass Reinforced Plastic (FRP) shell with polyester resin matrix
Inner surface coating with vinyl ester resin for chemical resistance
Integrated flanges and nozzles for cooling line connections
Base Foundation Preparation – reinforced concrete pad
Tank Assembly & Sealing – on-site filament wrapping and inspection
Piping Integration – connection with cooling tower outlet/inlet lines
Testing & Commissioning – leak, pressure, and hydrostatic tests
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| Criteria | Carbon Steel Tank | FRP Tank |
|---|---|---|
| Corrosion Resistance | High maintenance (anti-rust coating) | Excellent (non-corrosive composite) |
| Weight | Heavy | 1/4 of steel weight |
| Thermal Conductivity | High (heat loss) | Low (better insulation) |
| Maintenance Interval | Every 2–3 years | Every 8–10 years |
| Estimated Service Life | 8–10 years | 20+ years |
After one year of operation, the client reported:
Zero leakage incidents
Stable cooling water quality
30% lower operating cost
Reduced downtime during maintenance cycles
| Cost Factor | Traditional Steel | FRP Tank |
|---|---|---|
| Initial Fabrication | 100% | 120% |
| Annual Maintenance | 100% | 60% |
| Cleaning Chemicals | 100% | 70% |
| Energy Efficiency | Base | +8–10% |
| Total ROI (5 years) | — | Payback in 3.5 years |
While FRP tanks required a slightly higher upfront cost, the long-term operational savings resulted in full payback within less than 4 years — primarily through reduced corrosion, minimal downtime, and chemical efficiency.
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The success of fiberglass tanks in this project extended adoption to other sectors:
Power generation plants – for demineralized and process water
Food & beverage industry – for hygienic storage of process liquids
Chemical plants – for safe containment of aggressive liquids
Each sector benefits from non-contaminating surfaces, UV stability, and customizable modular configurations.
Material innovation: Vinyl ester-lined FRP tanks withstand long-term exposure to chemical and thermal stress.
Lifecycle advantage: Doubling the service life compared to mild steel tanks.
Structural efficiency: 70% lighter, reducing transport and installation costs.
Sustainability: FRP materials support eco-friendly manufacturing through recyclability and reduced coating waste.
“After switching to FRP tanks, our cooling water system became stable, energy-efficient, and virtually maintenance-free.
The tanks have maintained excellent water quality and saved us nearly 40% on yearly maintenance.”
— Chief Plant Engineer, Southeast Asia Manufacturing Group
This case demonstrates how industrial FRP tanks deliver both engineering and economic benefits in cooling and process applications.
With durability, corrosion resistance, and low maintenance, they outperform conventional metal tanks in every lifecycle stage.
Contact GTOFRP for industrial fiberglass tank solutions →
