Step-by-Step Guide to Lining the Interior of a Bulk Tank

July 19, 2025
9:43 am

This guide outlines the process for lining the interior of a bulk storage tank, from preparation through application, while emphasizing safety and compliance. Each section details critical steps and considerations to ensure a durable lining and a safe work environment.

1. Equipment Used

Before starting, gather all necessary tools, machinery, and safety equipment. Proper equipment ensures efficiency and safety throughout the tank lining process. Key items include:

Surface Preparation Equipment

An abrasive blasting system (high-capacity air compressor, blast pot, hoses, and nozzle) capable of maintaining about 100 psi at the nozzle for effective blasting
Choose appropriate abrasive media (e.g. garnet, aluminum oxide, or copper slag) that is clean, dry, and angular
Moisture traps and oil separators for the air supply (to ensure dry, oil-free air) are needed
Tools for pre-cleaning such as brushes, scrapers, or high-pressure washers
An industrial vacuum for cleanup of debris and dust

Application Equipment

An airless paint spray pump with the proper tip size for the lining material, along with spray gun and high-pressure hoses
Ensure all spray equipment is clean, in good working order, and properly grounded (earthed) to prevent static discharge
Mixing tools (mixing paddle and drill, measuring cups) for two-component linings
Rollers and brushes for touch-ups or stripe coating on welds and edges
Wet film gauges to monitor applied thickness
Dry film thickness (DFT) gauges on hand for quality checks
If required, have a high-voltage holiday detector for checking pinholes after curing

Safety Equipment

Personal protective equipment (PPE) is crucial. This includes:
- An abrasive blasting hood or helmet with supplied air
- Heavy-duty blast suit or coveralls
- Leather gloves
- Safety boots
- Hearing protection
For lining application:
- Respirators with appropriate cartridges (or supplied-air respirators) to guard against solvent vapors or isocyanates
- Chemical-resistant coveralls
- Gloves and eye protection
Confined space safety gear is required since the tank interior is a permit-required confined space:
- A calibrated multi-gas detector (to test oxygen levels and detect toxic or flammable gases)
- A tripod or davit with a full-body harness and lifeline for entrants
- An emergency retrieval system
Intrinsically safe lighting system (explosion-proof lights) for inside the tank
Ventilation fans with ducting to supply fresh air and exhaust fumes
Fire extinguishers nearby if using flammable materials
First aid equipment on site

Environmental Control Equipment

Ventilation blowers, dehumidifiers, heaters, or air conditioning units as needed to control the environment inside the tank
These help maintain proper temperature and humidity during blasting and coating
Sufficient ventilation and, if necessary, dehumidification should be available to keep the steel surface dry and the ambient conditions within the coating manufacturer’s specifications
Dehumidifiers can prevent flash rust by keeping relative humidity low
Heaters can ensure the substrate stays above minimum temperature requirements for the lining to cure properly

Staging and Access

If the tank is large, you may need to erect scaffolding or work platforms inside to reach all surfaces
Scaffolding boards or platforms should ideally be metal grating to prevent accumulation of abrasive and to allow airflow
If wooden boards are used, ensure they are clean (new and free of contaminants) so they do not introduce dirt or oil
All scaffolding and rigging should be secure and meet safety standards (guardrails, proper load rating)
A safety harness and fall arrest system is necessary if working at height inside the tank or entering through a top manway

Having all these tools and equipment ready and in good condition before you begin will help the lining job proceed safely and efficiently.

2. Surface Preparation

Proper surface preparation is critical to the success of any tank lining. The goal is to ensure the interior steel is clean, free of contaminants, and suitably roughened for the lining to bond. Follow these steps to prepare the tank interior:

Initial Cleaning and Degassing

Ensure the tank is completely emptied of its contents
For tanks that held chemicals or petroleum, thoroughly degas and ventilate the tank before entry
Remove any sludge or residual product from the floor and walls
All vapors should be purged until testing confirms the atmosphere is safe for work (see safety section for atmospheric testing)
Lock out and tag out any connected lines or valves to isolate the tank

Degreasing and Washing

Remove oils, grease, or other residues from the steel surface
Perform a solvent wipe or wash in accordance with SSPC-SP1 (Solvent Cleaning) to eliminate grease and oily films
In many cases, a combination of cleaning methods is used:
- Apply an alkaline detergent or degreaser
- Scrub the surface
- Then rinse
High-pressure water washing or steam cleaning can be effective to lift off contaminants and old residues
After using any cleaning chemicals, rinse thoroughly with fresh water to remove soluble salts, detergents, or acid cleaners
Allow the interior to dry completely
(If flash rusting occurs from water washing, you may need to re-clean those areas or use inhibitors as per project specs.)

Inspection and Repairs

Inspect the interior for any structural issues
Ensure the tank is structurally sound (no thin walls or severe pitting that compromise integrity)
Complete any necessary hot work (welding repairs, adding patch plates, etc.) before proceeding, as welding after lining will damage the new coating
All welding or cutting on the tank must be finished and the tank cooled/ventilated of fumes before surface prep continues

Remove Loose Material

Strip out any existing liner or loose paint, if present
Old coatings that are failing should be fully removed to expose bare steel
Likewise, scrape off heavy rust scale or delamination
Hard deposits (like scale or sludge) should be chiseled or scrapped off
The abrasive blasting in the next step will take care of remaining rust and paint, but large deposits and thick coatings are easier to remove beforehand

Surface Profile Preparation

Smooth out rough welds and sharp edges by grinding
Weld seams, sharp corners, and any metal projections should be rounded or ground down
This prevents sharp burrs from protruding through the new lining and removes potential coating weak points
Grinding also eliminates welding spatters and splatter that could shield areas from being blasted
Aim for a slight rounding of edges and a generally uniform surface profile on weld beads
Bolted connections or other hardware inside the tank should be addressed as well (either removed for separate coating or prepared in place)
All surfaces to be lined should be accessible and exposed

Pre-Blasting Checks

Before abrasive blasting, ensure conditions are correct
Verify the steel surface is completely dry and the steel temperature is at least 5°F (3°C) above the dew point of the surrounding air
This prevents moisture condensation during blasting which would cause flash rust
It’s advisable to record the ambient temperature and humidity; if conditions are unfavorable (e.g. high humidity or very low steel temp), use dehumidification or wait for better conditions
Also, seal or cover any openings, valves, or instruments on the tank that could be damaged by blast media
For instance, if there are internal components not meant to be coated (like heating coils, gauges, etc.), protect them with plastic sheeting or other suitable covers to prevent blast impact and dust intrusion

By following these surface prep steps, the interior will be ready for abrasive blasting. Proper cleaning and prep ensure that the subsequent blasting can produce a clean, bondable steel surface. Any contamination left on the steel (oil, dirt, salts) could interfere with achieving the necessary surface profile and coating adhesion, so thorough preparation is essential.

3. Blasting Process

Abrasive blasting (sandblasting or grit blasting) is the primary method for achieving the required steel cleanliness and surface roughness (anchor profile) for a tank lining. This step profiles the metal and removes rust, mill scale, and old coatings. Key aspects of the blasting process include the choice of abrasive, blasting parameters, and containment/clean-up measures:

Abrasive Selection

Use a sharp, angular abrasive that can cut and clean the steel surface to the specified profile
Common choices include mineral abrasives like garnet, aluminum oxide, coal slag, or copper slag, which are hard and angular
These abrasives produce a good anchor pattern (surface roughness) for coating adhesion
The abrasive must be dry and free of contaminants; damp or dirty media can contaminate the steel or clog equipment
Avoid using silica sand as a blast media, as it contains free silica which poses serious health hazards (silicosis) and is often prohibited
Also avoid shot blasting with round steel shot for this purpose, because round shot tends to peen and polish the surface rather than roughen it, and it may not achieve the angular profile needed
If recyclable metallic grit is used, ensure it remains clean and free of oil or moisture; generally, using fresh, quality abrasive for tank internals is recommended for best results (recycling abrasive in a tank job can introduce contaminants if not carefully managed)

Blasting Standards and Profile

The interior steel should be blasted to a high-quality finish such as near-white metal or white metal cleanliness, depending on project specs
Typically, the standard is SSPC-SP10 / NACE No.2 Near-White Metal or better, which means nearly all rust, mill scale, and old paint are removed
In some cases, a full SSPC-SP5 / NACE No.1 White Metal Blast is specified, indicating the steel is 100% free of visible contaminants
Achieving this often requires skill and possibly a second pass or touch-up in difficult areas
The surface profile (peak-to-valley roughness) created by the abrasive should meet the lining manufacturer’s recommendation (often around 2.5–3.5 mils for tank linings)
Use an abrasive grit size that will produce this profile – for example, medium garnet or coal slag can typically achieve a ~3 mil profile on steel
It’s good practice to blast a small test patch and measure the profile using replica tape or a profile gauge to verify you’re getting the desired roughness
All surfaces, including corners, welds, and around fittings, must be thoroughly blasted
Hard-to-reach spots may need specialized nozzles or hand tooling if the blast stream can’t directly hit them

Blasting Technique

Maintain adequate air pressure and volume throughout blasting
Ensure the compressor provides at least 7 bar (100 psi) at the nozzle under load, as high energy is needed to properly clean and profile the steel
Lower pressure can result in poor cleaning and an inconsistent profile
Use a nozzle appropriate for the compressor output (nozzle size too large can drop the pressure)
Check that the compressed air is dry and oil-free – perform the ASTM D4285 blotter test by blasting air (no abrasive) on a white cloth for 30 seconds to confirm no oil or moisture is present
Hold the blast nozzle at the correct distance (typically 6–12 inches from the surface) and at an angle that effectively cleans but doesn’t gouge the steel
A systematic approach (blasting in sections or patterns) ensures even coverage
Overlap blast areas to avoid any missed spots or stripes of lesser cleanliness
The blaster should also periodically inspect the surface (often by stopping and using a flashlight) to ensure completeness

Containment and Ventilation

Blasting a tank interior generates a large amount of dust and spent abrasive
Although the tank shell itself provides containment, you must control dust to protect workers and the environment
Keep the tank openings (manways) closed as much as possible during blasting, except for necessary ventilation extraction points
Use containment barriers or curtains at openings or around the tank if it’s open, to isolate the operation from other workers and prevent dust escape into the environment
Employ an exhaust ventilation system:
- Position an extraction fan with ducting at an upper opening to draw out dusty air
- An intake fan to blow fresh air in (ideally at a lower point, to push dust upward toward the exhaust)
This creates a flow-through ventilation that clears dust and maintains visibility inside
Proper ventilation during blasting not only protects workers (preventing dust buildup and allowing the blaster to see), but also helps keep the relative humidity low, which is important to minimize flash rust
If the tank is extremely large or the blasting is producing heavy dust, consider doing the work in sections or using dust-collector attachments on blast nozzles to reduce dust
For outdoor tanks, blasting inside still requires containment of what comes out; use tarps and negative air machines if needed to capture debris, per environmental regulations

Personnel Safety During Blasting

Only qualified blasters wearing appropriate PPE should be inside during blasting
The blaster must wear a Grade-D air supply with a blasting helmet, as well as the full suit, gloves, and hearing protection (abrasive blasting in a confined metal tank is extremely loud)
No other trades should be in the immediate area — unauthorized personnel should be kept away from the tank during blasting due to flying abrasive and silica or dust hazards
The attendant outside should also wear a dust mask or respirator if there’s any exposure to escaping dust
Rotate blasters as needed to prevent fatigue; blasting is strenuous work especially in a respirator suit

After-Blast Cleaning

Once the abrasive blasting is complete for the entire interior, thoroughly remove all blasting residue
This is a crucial step: all dust, spent grit, and debris must be cleared out so it does not interfere with coating adhesion
Use industrial vacuum cleaners (with filters suitable for fine dust) to vacuum all surfaces, starting from the top of the tank downwards
Pay special attention to horizontal surfaces, ledges, stiffeners, and corners where abrasive might collect
It’s often recommended to follow vacuuming with blowing down the surfaces using clean, dry compressed air, and then vacuuming once more
The end goal is no visible dust
Perform a visual inspection (with good lighting) in hard-to-see areas, possibly using mirrors, to ensure no pockets of dust or spent abrasive remain
Also, be careful not to touch the freshly blasted steel with bare hands; oils from skin can contaminate it
If any oil, grease, or other contamination is detected on the bare steel, remove it and reblast that area
Likewise, if flash rusting has begun (a slight orange/brown tint on the steel) because too much time passed or humidity got in, those areas should be lightly reblasted to restore the proper class of cleanliness

Maintaining the Blast Standard

Immediately after blast-cleaning and dust removal, the surface should meet the specified cleanliness (e.g. near-white metal)
Coating should ideally commence as soon as possible after blasting, certainly within a few hours and before any visible rust returns
Industry practice is often to line the same day as blasting for tanks, to avoid rework
If any delay occurs or moisture condenses and rust blooms, you’ll need to re-clean or re-blast affected spots
Some projects use a holding primer (a thin coat applied right after blasting to seal the surface and prevent rust) if there’s a long delay before full lining application; this can be done but only with a primer that is compatible with the final lining system and approved by the lining manufacturer
Generally, continuous dehumidification inside the tank can also prevent rust bloom if coating is delayed

By executing the blasting process with the right abrasive, technique, and containment, you will obtain a properly roughened, clean steel surface. This surface is essential for the lining material to adhere well and perform over the long term. Proper blasting is often the most labor-intensive part of tank lining, but it directly impacts the quality and lifespan of the liner.

4. Application Process

With the tank interior cleaned and blasted to specification, the next phase is applying the lining material. The application process must be carried out meticulously to ensure a uniform, defect-free liner. It involves controlling the environment, mixing the product correctly, applying it in the prescribed manner, and allowing proper curing. The general steps are as follows:

Environment Check and Climate Control

Before coating, confirm that ambient conditions are within the lining manufacturer’s recommended range
Typically, the steel temperature must be at least a few degrees above the dew point (commonly 3–5°C (5–9°F) above dew point) to prevent moisture
Relative humidity inside the tank should be controlled (often kept below ~85% or as specified)
Use dehumidification or heating as required to maintain these conditions
Ensure the tank is free of any condensation or wet spots – the surface should be completely dry
Ventilation should be adjusted during coating to provide fresh air for workers and to exhaust solvent vapors, but not so intense that it blows dust onto wet paint or causes the coating to dry too quickly
If working in cold conditions, the tank (and coating materials) may need to be heated to achieve the minimum application temperature per the Product Data Sheet (PDS) of the lining
Do not proceed with coating if conditions are outside of spec, as this can lead to adhesion failure or improper curing

Final Surface Inspection and Cleaning

Just before coating, do a final check of the blasted surface
It should be at the specified cleanliness (no rust, no residues)
Tack cloths or clean, dry air can be used to remove any last traces of dust
Verify no oil from tools or fingerprints have appeared
All masking of areas not to be coated should be in place (for instance, mask off nozzle flanges or gasket surfaces, if they must stay uncoated)
Also, set up adequate lighting inside the tank for the coating application, as good visibility is crucial to ensure complete coverage

Mixing the Lining Material

Prepare the lining material according to the manufacturer’s instructions
Most industrial tank linings are multi-component coatings (e.g. a two-part epoxy or polyurethane)
Mix Part A and Part B in the specified ratio using a mechanical mixer
Mix until the coating is uniform (typically several minutes) – improper mixing can result in uncured spots
If the product requires an induction time (a wait time after mixing before application), observe it as directed in the PDS
Only mix as much material as you can apply within its pot life (working life before it thickens or cures in the pot)
Use clean mixing pails and do not contaminate components (use separate utensils for each part until mixing)
For some solvent-free or thick linings, plural-component spray equipment might be used to automatically mix at the nozzle – ensure the equipment is calibrated and tested if so
For single-component linings (like some moisture-cure urethanes), stirring the paint to homogeneity is typically needed
In all cases, strain the coating through a paint filter when pouring into the spray equipment to catch any clumps or unmixed portions

Stripe Coating

Before applying the full coat to all surfaces, it is a best practice to stripe coat all critical areas by hand
Using a brush (or roller where appropriate), apply a stripe of the lining material to edges, weld seams, bolts, rivets, or corners – essentially any sharp edge or area that is difficult to fully cover with spray
Stripe coating ensures these areas receive adequate thickness, as spray guns tend to deposit a thinner film on edges
Use the same lining material (mixed batch) for stripe coats, and work it well onto the surface
Allow the stripe coat to become tacky (or as specified, sometimes it should dry to touch) before the overall spray so that it doesn’t get blown off by the spray but also merges with the next coat
This step greatly improves the corrosion resistance at seams and edges

Full Lining Application

Now apply the lining to the entire interior surface, usually using airless spray equipment for efficiency and even coverage
Begin at the top of the tank and work downward in sections, to avoid overspray settling on already coated areas below
Hold the spray gun at the proper distance (typically 12–18 inches unless specified otherwise) and perpendicular to the surface to get an even coat
Use a spray tip size and pump pressure suitable for the coating’s viscosity – high-solids linings may need a large tip and a powerful pump
Ensure the pump maintains enough pressure to atomize the coating properly (avoid “fingering” in the spray pattern)
Apply in smooth, overlapping passes, aiming for the specified wet film thickness each pass
It’s important to achieve the target dry film thickness (DFT) for the lining; apply the coating to the recommended thickness per coat (e.g., if 20 mils DFT is needed in two coats, apply ~10 mils DFT per coat, adjusting for any shrinkage)
Use a wet film thickness gauge during application to spot-check that you are applying sufficient coating
If the project requires multiple coats (e.g., a primer and two build coats, or two coats of a high-build liner), follow the specified sequence
Typically, one would apply the first full coat, let it cure to the proper stage, then apply the second coat within the prescribed recoat window
Pay attention to recoat times: minimum time so that the first coat is firm enough not to be damaged, but maximum time so that the second coat chemically bonds without extensive surface prep
If you exceed the recoat window, you may need to lightly abrade the first coat to ensure adhesion of the next coat
While spraying, also be vigilant for any drips or sags, especially on vertical surfaces
It’s better to apply two moderate coats than one excessively heavy coat which might sag
If any areas are missed or end up thinner, you can touch them up (preferably while the coating is still wet or during the second coat)
Maintain a wet edge to avoid dry spray
In confined spaces, coating edges of beams or behind ladders can be tricky – use brushes or rollers in those spots if needed to ensure complete coverage
Keep the coating well-stirred if it has heavy solids (to prevent settling in the pot)
If work is paused, do not leave mixed paint in hoses or spray guns for too long, as it can cure and clog the equipment; flush equipment with solvent if there will be a long break

Curing and Environmental Control

After application, the lining needs to cure properly
Continue to monitor the environment inside the tank during curing
Maintain temperature and humidity within the curing specifications of the product
Many epoxy or polymer linings will cure faster in warmer conditions and may cure very slowly (or not fully) if temperatures drop too low
If the tank is in a cold environment, you might use portable heaters (indirect heat to avoid CO or fire hazard) to keep the tank warm
Be cautious: do not overheat or create hot spots; too rapid drying, especially of solvent-based coatings, can lead to solvent entrapment or cracking
A gentle, even heat and good airflow is ideal
Likewise, ensure the ventilation is still running to exhaust fumes during the initial cure phase — many coatings release solvents or fumes for several hours
Follow the manufacturer’s stated cure times: these might include a “dry to recoat” time, a “dry to handle” time, and a full cure time (which could be 24 hours to several days, depending on the chemistry)
It’s often recommended to do no heavy cleaning or immersion of the lining until it’s fully cured
If the lining is plural-component (catalyzed), avoid any exposure to moisture or chemicals during curing that could affect the chemical cure

Quality Checks (DFT and Holiday Testing)

Once the coating has cured enough to walk on (often called “dry to handle”), perform a thorough inspection
First, verify the dry film thickness at multiple locations using a calibrated DFT gauge (magnetic or ultrasonic gauge appropriate for the substrate)
Ensure the thickness meets the specification everywhere: critical areas like edges or welds should meet the minimum, and overall no area should exceed the maximum thickness (excessive thickness can cause its own problems)
If you find thin spots (below spec), you may need to apply an additional touch-up coat in those areas, provided it’s within the allowable recoat period or after proper surface prep if it’s outside that period
Next, for linings that are protective against corrosion (non-conductive coatings), a holiday detection test is usually carried out
Using a high-voltage holiday detector (spark tester), systematically sweep the probe over the entire lined surface to detect any pinholes, voids, or misses in the coating
Set the test voltage according to the coating thickness and manufacturer’s recommendation (for example, a rule of thumb is around 100 volts per mil, but follow the standard or PDS) – too low might miss holidays, too high could damage the coating
If a holiday (pinpoint defect) is found, mark the spot for repair
Typical repair involves lightly sanding around the defect and applying a patch of the lining material according to spec
Another quality check is visual: ensure the entire surface is covered and there are no areas with improper finish (like heavy orange peel, runs, or blistering)
Also, if the tank lining is for chemical service, some specifications call for solvent wipe tests or hardness tests to ensure cure

Curing Completion and Return to Service

After any touch-ups, allow the lining to fully cure per the manufacturer’s guidelines before placing the tank back in service
Full cure may take several days to a week or more, depending on the product and conditions
During this time, keep the tank isolated – no contaminants should be introduced
It’s wise to do a final inspection with the owner or inspector present once curing is done, to sign off that the lining is satisfactory
Document all measurements (DFT readings, environmental conditions, batch numbers of products used, etc.) as part of the quality assurance record

Throughout the application process, adherence to the product data sheets and project specification is crucial. Each coating system may have unique requirements (for example, some linings might need post-curing with heat, or specific recoat times). By carefully applying the coating in the correct conditions and thickness, you will create a durable, continuous liner inside the tank.

5. Safety and Regulatory Considerations

Lining the interior of a bulk tank involves hazards that must be managed in compliance with safety regulations (OSHA standards in the U.S.) and environmental laws (EPA and local regulations). The following are key safety and regulatory considerations:

Confined Space Entry

The interior of a tank is a permit-required confined space under OSHA definitions, meaning it has limited entry/exit and may contain hazardous atmospheres
Before anyone enters the tank, a confined space entry permit must be in place
Atmospheric testing is mandatory: test the air for:
- Oxygen level (must be 19.5%–23.5% O₂)
- Flammable gases (below 10% of the LEL)
- Toxic vapors (below permissible limits)
Use a calibrated multi-gas detector to check all levels of the tank (gases can stratify, so test low and high points)
If the tank previously contained hazardous chemicals, ensure no harmful vapors remain
Continuous forced-air ventilation is required during entry and work to prevent the buildup of fumes or lack of oxygen
An air mover/blower should be set up to supply fresh air and exhaust stale air; keep it running the entire time workers are inside
Establish an emergency rescue plan before entry: assign a trained attendant to stand watch outside the tank at all times (they should have no other duties)
The attendant will monitor the entrants and be ready to call for rescue or assist from outside if something goes wrong
Ensure that a tripod, winch, or other retrieval system is set up at the entry manway so that an unconscious worker can be pulled out quickly if needed
All entrants should wear a full-body harness connected to a lifeline as a precaution, as well as any other equipment required by the permit
Communication (radio or hand signals) between the inside team and attendant must be maintained
Also, lockout/tagout any energy sources connected to the tank (such as agitators, pumps, or valves) so nothing accidentally introduces hazards while work is ongoing

Personal Protective Equipment (PPE)

OSHA regulations require proper PPE for all workers involved in abrasive blasting and coating (29 CFR 1910 Subpart I)
During abrasive blasting, blasters need:
- A specialized abrasive blasting respirator (a Type CE supplied-air hood that covers head, neck, and shoulders)
- Heavy-duty protective clothing: abrasive-resistant suit or coveralls
- Leather gloves that cover the full forearm
- Steel-toe boots
- Hearing protection (blasting noise can exceed 100 dB)
Anyone assisting (e.g. the pot tender) should at least have a high-quality respirator (if not supplied air, then an N95/P100 for nuisance dust or better depending on exposure) and eye/hearing protection when near the operation
During coating application, especially with solvent-based or chemically curing linings, workers must wear:
- Respirators equipped with organic vapor cartridges and particulate filters or use supplied air, as appropriate
- Chemically resistant gloves (to avoid skin contact with coating)
- Safety goggles or face shields (for mixing operations or if splash hazard)
- Coveralls or Tyvek suits to keep chemicals off skin
Many tank lining products contain solvents or isocyanate curing agents that are hazardous in enclosed areas; OSHA’s Respiratory Protection standard (29 CFR 1910.134) must be followed, including fit-testing and training if air-purifying respirators are used
When working at heights on scaffolds inside the tank, use a safety harness and lanyard tied off to an anchor point as fall protection, even inside the tank, if there’s a risk of falling off platforms

Worker Training and Communication

Ensure all workers are trained for their tasks and aware of the hazards
Abrasive blasters and coating applicators should be trained in safe operation of equipment and PPE use
Confined space entry personnel must be trained per OSHA 1910.146 – this includes entrant, attendant, and supervisor roles
Conduct a safety briefing each day before work, reviewing emergency procedures and any new hazards
Follow OSHA’s Hazard Communication standard: have Safety Data Sheets (SDS) on site for all chemicals (coatings, solvents, etc.), and make sure workers understand the risks (e.g. toxicity, flammability)
Post signs or barricades outside the tank area warning of “Confined Space – Entry by Permit Only” and “No Unauthorized Entry” to keep others out
Also, use signs or locks to ensure no one inadvertently turns on any equipment connected to the tank (lockout/tagout)

Ventilation and Air Monitoring

As noted, continuous ventilation is critical
Test the air periodically during the work, not just once at the start
Conditions can change (for example, solvents evaporating during coating can raise vapor levels quickly)
Use explosion-proof ventilation fans to avoid ignition of flammable vapors
If solvent vapors or dust levels cannot be controlled to stay below OSHA permissible exposure limits, stop work and upgrade controls – for example, increase ventilation, reduce the amount of solvent in use, or rotate workers out more frequently
Never use pure oxygen to ventilate – only air
If using gas-powered equipment (like some air compressors or heaters), keep them outside and direct exhaust away from the tank intake to avoid carbon monoxide buildup
For hot work (if any cutting/welding needed during prep), obtain a separate hot work permit and ensure the interior is vapor-free (often hot work is forbidden once lining starts, to avoid igniting fumes)
Also, no smoking or open flames anywhere near the tank during cleaning, blasting, or lining, as residual vapors or coating solvents could ignite

Environmental Protection and Waste Disposal

Lining a tank can generate hazardous waste, especially from blasting
Old paint chips and spent abrasive may contain lead, chromium, or other toxic substances, classifying them as hazardous waste under EPA/RCRA regulations
All waste (sludge, blasting media, used solvent, etc.) should be collected and disposed of in accordance with environmental laws
Do not allow blasting debris or paint waste to escape to the outside ground or drains
Use heavy-duty tarps or containment systems to capture all debris
After blasting, containerize the spent media and have it tested if required to determine proper disposal (hazardous vs non-hazardous)
Usually, contaminated blast media must go to a permitted facility (not regular trash)
Liquid wastes like solvent from equipment cleaning must likewise be captured and disposed of properly – never poured down drains
If the project involves any emissions of dust or solvent, ensure compliance with air quality regulations: for example, EPA and local air districts may limit VOC emissions or require filters on exhaust
Using low-dust abrasives and ventilating through dust collectors can help minimize environmental release
For indoor facilities, ensure neighboring areas are protected from dust infiltration (using plastic sheeting on vents, etc.)

Regulatory Compliance

Comply with all relevant OSHA standards, which include not only the confined space and PPE standards mentioned but also those for abrasive blasting and painting operations
OSHA has guidelines for ventilation during blasting and spraying (e.g., 29 CFR 1910.94), which specify using exhaust ventilation and respiratory protection
Also follow any industry standards or owner requirements, such as API Recommended Practices for tank lining if applicable, or NACE/SSPC guidelines for quality
If the tank is an underground storage tank (UST) for petroleum, note that the EPA requires internal lining to meet certain criteria and inspections (per 40 CFR Part 280 and API RP 1631)
Ensure documentation is kept for the lining work: date, products used, thickness readings, etc., as these might be required for regulatory records or future inspections (for example, USTs with internal linings must be inspected periodically to confirm the lining’s integrity)

Emergency Preparedness

In addition to a rescue plan for confined space, have general emergency measures in place
This includes first aid training for some crew, a stocked first aid kit on site, and a means to contact emergency services quickly (a phone or radio on site)
If working at a remote site, plan how to evacuate an injured worker
Be mindful of heat stress when workers are in protective gear inside a closed tank – provide rest breaks and hydration
Conversely, in cold weather, ensure workers stay warm during breaks

Final Safety Walkthrough

Before declaring the job complete, do a final walkthrough for safety: make sure all tools and equipment have been removed from the tank (no debris left behind), all temporary power or ventilation is secured, and no hazards remain
Only then close up the tank
If the tank was inerted for safety, purge it back to normal atmosphere properly
Remove all lockout tags and barriers after work completion and when the area is safe

By rigorously following safety protocols and regulatory requirements, you protect the workers performing the lining and avoid environmental or compliance issues. Safety is integral at every step – from wearing the right PPE during blasting, to ventilating and monitoring the air, to handling wastes responsibly. Lining a tank is a complex task, but with careful planning and adherence to OSHA/EPA standards, it can be done safely and successfully.