The Top 5 Aboveground Storage Tank Coating Challenges (AST Coatings in 2025)

7 min

About Qlayers

17 July 2025

top 5 challenges in storage tank coating AST coating

In 2025, aboveground storage tank (AST) coating challenges are intensifying, as tank owners and asset managers face stricter VOC regulations, rising industrial paint costs, and pressure for more sustainable, automated coating solutions. In this post, we dive into the top 5 storage tank coating challenges and how Qlayers’ robotic systems optimize aboveground storage tank (AST) coatings.

Industrial storage tank coatings are under more pressure than ever. In 2025, asset owners and coating contractors face a complex web of challenges—from tightening environmental regulations and volatile material prices to evolving performance standards and a shrinking skilled labor force.

Storage tanks, especially aboveground storage tanks (ASTs), are vital infrastructure for industries like oil & gas, chemicals, and energy. Yet maintaining their structural integrity and coating performance has never been more difficult, or more important. As climate conditions grow harsher and regulations tighten, storage tanks face increasing risk from wear and tear. Confined spaces, curved geometries, inspections, and high downtime costs make storage tanks uniquely difficult to coat effectively.

To stay competitive, companies must rethink traditional coating strategies. Robotic and data-driven solutions are emerging as a key answer. Embracing sustainable industrial coatings practices and innovative robotic coating systems isn’t just smart—it’s becoming essential.

1. Environmental Regulations for Storage Tank Coatings

Storage tanks, particularly those storing hazardous materials, must comply with strict environmental regulations. Across the globe environmental regulations are tightening, placing significant pressure on the industrial storage tank coatings sector.

In Europe, the Green Deal and the Zero Pollution Action Plan are setting ambitious goals. The UN’s Net-Zero Asset Owner Alliance calls for up to a 32% emissions reduction by 2025, and up to 65% by 2030. In China, the GB 30981-2020 coating standards and regional VOC limits are pushing manufactures to adopt low-emission materials and install automated VOC monitoring systems. Meanwhile in Singapore has implemented strict controls through the NEA (National Environment Agency) affecting lead, VOC, and waste regulations, including a ban on formaldehyde in interior paints by 2026 (1,2,3,4,5).

Additionally, U.S. facilities must adhere to the EPA’s Spill Prevention, Control, and Countermeasure (SPCC) rule, which prevents oil discharges into navigable waters, and industry standards like API 652, which provides guidelines for applying protective linings to the bottoms of aboveground storage tanks (ASTs) to prevent internal corrosion (6,7).

Ensuring compliance with standards requires meticulous maintenance, accurate emission quantification, and adherence to safety protocols to prevent environmental contamination. During third-party API 653 audits, even minor coating failures or incorrect waste disposal can lead to leaks, soil contamination, or costly shutdowns.

As a result, industrial coating clients are demanding AST coating solutions that are more sustainable, more transparent—and just as cost-effective. Companies that fail to adapt face shrinking market access, regulatory fines, or reputational damage.

Qlayers’ Solution

Lower Environmental Impact: Our robotic systems cut GHG emissions, waste, smog potential, ecotoxicity, and human carcinogenic toxicity by reducing toxic air pollutants being released in the environment

Ultra‑Low Overspray: Our robotic solution cut overspray by up to 90%, minimizing VOC and plastic pollution

Energy Savings: Consistent application reduces rework and downtime, cutting energy use and GHG emissions by 5–30%

Sustainability Dashboard: Clients can monitor sustainable industrial coatings metrics and real-time KPIs of their projects, simplifying predictions, reporting and decision making

Learn more about how Qlayer contributes to sustainability.

2. Rising Material and Energy Costs in AST Coatings

Global economic volatility continues to cause mounting challenges in the coatings industry. Fluctuating market prices and inflation have driven up costs of key ingredients like resins, solvents, and pigments (8).

In Saudi Arabia—a major hub for the oil and gas industry—thousands of aboveground storage tanks require regular maintenance and recoating every year. An asset owner responsible for 30 storage tanks with a 73m diameter and 22m height with a total coated surface area of 192,480 m2. This AST project would require approximately 78 855L of primer/intermediate (Sigmacover 350), 55 672.5L of topcoat (Sigmadur 550H) with traditional coating methods.

With paint prices ranging from 15 to 25€ (primer) and from 28 to 38€ (topcoat) per liter, a 15% increase in paint costs would result in 612 039.50€ additional expenses for coating materials alone, with a total of 4,698,969.50€ (9,10) (This calculation is approximate, it is based on data from one of our case studies, if you want to learn more about how we did this calculation download this case study or contact us)

In Saudi Arabia—a major hub for the oil and gas industry—thousands of aboveground storage tanks require regular maintenance and recoating every year. In this type of harsh climate, that is detrimental to both assets and workers, even small inefficiencies in the coating process can result in serious cost overruns. Choosing the appropriate coating material is also crucial for effective corrosion under insulation (CUI) protection. Geopolitical uncertainty and supply chain disruptions only add to the pressure, forcing manufacturers to prioritize efficiency—without sacrificing quality. (11)

Qlayers’ Solution

Material Savings: Our spray shielding system reduces overspray cutting paint waste by 35%, saving money, energy and millions of liters of paint on multi‑tank tank farm refits

Cost Forecasting: Real-time analytics and usage data support accurate budgeting and purchasing, allowing users to see the real costs and efficacy of their coating efforts, helping stakeholders plan for market volatility

Compatibility and Versatility: Our robots are compatible with most industrial coatings. Extensive testing and experience allow us to advise clients on the best paint application settings for each project, ensuring application quality and cost efficiency. If you’re planning a project with a specific type of coating, we’d be happy to explore compatibility together. Simply fill out this form to start the conversation.

3. Maintaining Coating Consistency and Quality on Large Storage Tanks

As industries demand greater durability, today’s performance coatings must endure some of the harshest operational environments and meet strict standards such as the ISO 12944 for tank exterior coating for corrosion protection (11).

Modern coatings, such as corrosion-resistant coating or UV-resistant coating, are expected to provide long term corrosion and UV protection and stability even under extreme weather conditions. But even the most advanced formulation can fail if it’s applied inconsistently.

Inadequate surface preparation, incorrect application techniques, and environmental conditions and paint processing can reduce the effectiveness of protective coatings and lead to premature asset failure (12,13). Even with proper surface preparation, application challenges like streaking, bubbling, and uneven film thickness often occur.

Many facilities still rely on manual application methods, which leave room for variability and coating defects. Robotic solutions can enhance both the blasting and coating processes by delivering precise, controlled application—ensuring consistent spray angle, pressure, speed and distance for reliable, high-quality results every time.

At Qlayers, we’re transforming this narrative.

The 10Q robotic coating system, was developed with sustainability at its heart and directly addresses the environmental inefficiencies of traditional coating methods.

Our “no overspray technology” drastically decreases the amount of paint and plastics released into the environment and uses up to 35% less paint, reducing emissions from production, transportation and waste. Overall, our technology can reduce GHG emissions per job by up to 30%. Also, VOC emissions are reduced by around 35%, improving air quality and reducing impact on human and ecosystem health.

Qlayers’ Solution

Programmed Precision: Our robotic systems maintain an estimated film‑thickness of approximately ±10% (e.g. for a 300 µm dry film thickness (DFT) target, the expected variation is around ±30 µm) and achieve 90% transfer efficiency with virtually no overspray

Automated Control: Built-in sensors track temperature and pressure in real time to maintain ideal spraying speed control

Faster Cycle Times: Our robotic systems drastically reduce project timeline overall minimizing downtime and maximizing ROI

4. Automating AST Coatings: Technological Integration and Data

While Industry 4.0 is driving transformation across sectors. API 653 audits, EN ISO 16961-2015, SY/T 5921-2011, require detailed records—coating maps, environmental logs, and inspection notes to prove tank integrity. Yet many coating contractors still log in data manually or use outdated systems for asset lifecycle management, such as manual data entry, isolated workflows, and limited process visibility.

This lack of insight into application quality, material usage, environmental conditions, and equipment performance makes it difficult to monitor the process and ensure compliance, or offer the transparency that clients nowadays expect. As remote monitoring, traceability, and digital quality assurance become industry standards, the lack of digital maturity poses a significant competitive risk (13).

Automation can optimize coating quality through real-time adjustments. Yet, integrating new technologies into traditional workflows remains a challenge for many operators, particularly in legacy environments.

Qlayers’ Solution

Data‑Driven Insights: Our digital dashboards and automated logs give coating process optimization data for every project, boosting transparency and performance

Future‑Proof Automation: Our technology is designed for integration with Industry 4.0 standards, helping you stay ahead of market demands and evolving industry trends through research and innovation

Operator Training: We provide operator training for all of our clients as well as on-site and/or remote supervision and support. This allows our clients to integrate and implement our coating robotic solution swiftly, maximizing ROI.

5. Workforce Shortages and the Skills Gap in Storage Tank Painting

The industrial coatings sector is facing a growing workforce challenge, driven by an aging labor force, a shrinking talent pipeline, and the physically demanding nature of the work. With the average professional coating applicator approaching 50 years of age, and younger professionals opting for safer, more tech-forward careers, the gap is widening (14).

Health and safety concerns—such as working at heights, prolonged exposure to volatile organic compounds (VOCs), and repetitive physical strain further reduce the appeal of manual coating roles. In regions like the Middle East, climbing scaffolds on a 45 m tank shell in the Persian Gulf at 50 °C is a logistical nightmare, making manual application dangerous or impossible (15).

At the same time, the role of the industrial painter is changing. As new tools and technologies enter the market, painters are expected to operate advanced equipment—requiring both mechanical and digital skills. Learn more about the skills gap in the coating industry.

Qlayers’ Solution

Remote Operation: Robots reduce the need for large on-site crews, and take over high‑risk working conditions

Remote Control and Optimized Workflow: Our robotic coating robot is easily controlled by a remote and monitored by trained operators, this optimizes the coating process, making it faster, more proficient and productive.

Job Enrichment: By automating repetitive and dangerous tasks, Qlayers enables workers to take on higher-value responsibilities in supervision, analysis, and maintenance.

Tech-Driven Careers: Qlayers’ robotic technology brings a modern, digital dimension to the coating industry, helping to attract future generations, and moving beyond the outdated blue-collar image.

Conclusion

The industrial storage tank coatings sector stands at a critical juncture, facing a convergence of demanding environmental regulations, volatile markets, escalating performance expectations, the imperative of digitalization, and a rapidly evolving workforce.

These five challenges are deeply connected. Together, they’re driving a need for smarter, more sustainable, and more automated solutions. Companies that embrace advanced, data-driven technologies today will be better positioned to stay compliant, competitive, and profitable tomorrow.

At Qlayers, we’re helping lead that transformation. Our robotic coating systems, purpose-designed for ASTs coating, deliver consistent, high-quality results—faster, safer, and with far less waste. By combining precision application with built-in analytics and sustainability features, our technology helps build a coating process that’s leaner, greener, and future-ready.

Ready to overcome your industrial coating challenges? Contact the Qlayers team today to schedule a demo or a consultation

Resources

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