From UV radiation and extreme heat to humidity and freeze/thaw cycles, the environment surrounding your facility can accelerate wear, reduce elasticity, or even cause early failure in rubber-lined systems. Here’s what you need to know, and how you can counteract mother nature’s toll on your equipment. 

The Role of Rubber Lining in Harsh Environments

Rubber linings are commonly used in industries like mining, chemical processing, water treatment, and power generation. These linings are engineered to withstand these industries’ harsh exposure, but their performance can be compromised when subjected to intense weather-related stress, particularly in outdoor applications.

Environmental stress can cause:

• Hardening or embrittlement of the rubber
• Surface cracking or crazing
• Loss of flexibility and elasticity
• Delamination or debonding from the substrate
• Accelerated wear and tear

Over time, these effects can reduce containment integrity, increase the risk of leaks, and shorten the overall lifespan of the lining.

Top 4 Weather Conditions That Impact Rubber Lining

These environmental conditions can lead to premature failure of industrial rubber linings if no special prohibitive measures are in place. 

1. Extreme Temperatures

Rubber materials are sensitive to temperature fluctuations. High heat can accelerate oxidative degradation, causing the rubber to harden and lose flexibility. In colder climates, rubber becomes more brittle and prone to cracking.

• At high temperatures (above 140°F/60°C), most rubber compounds begin to lose mechanical strength.
• In freezing conditions, rubber can shrink and crack, especially if moisture is present in or beneath the lining.

Selecting rubber compounds rated for the expected temperature range is essential for maintaining performance. For example, EPDM (ethylene propylene diene monomer) rubber performs well in both hot and cold conditions, while natural rubber is less tolerant of heat and UV.

2. UV Exposure

Ultraviolet radiation from the sun can break down molecular bonds in rubber, a process known as UV degradation. Over time, this leads to fading, discoloration, surface chalking, powdering, microcracking, and/or hardening.

Rubbers like chlorobutyl and EPDM offer superior resistance to UV degradation. In high-exposure environments, adding a UV-resistant topcoat or paint layer can significantly extend the life of the lining.

3. Humidity and Moisture

High humidity accelerates the aging process of rubber and promotes the growth of mold, algae, or microbial contamination under the lining. Moisture ingress can also weaken the adhesive bond between the rubber and substrate.

In tropical or coastal climates, where humidity is consistently high, it’s important to:

• Use closed-cell rubber linings to limit water absorption
• Seal all edges and seams properly during installation
• Conduct routine inspections to detect bubbling or debonding

4. Freeze/Thaw Cycles

Regions that experience frequent freeze/thaw cycles pose a unique challenge. Water that penetrates under the lining or into surface imperfections can expand as it freezes, exerting pressure that leads to cracking or spalling of the rubber.

This cycle of freezing and thawing repeatedly stresses the lining system, often causing failure over time unless proactive measures are taken.

How to Avoid Weather Damage to Industrial Rubber Lining

You can’t control the weather, but you can take several steps to prolong the lifespan of rubber-lined assets amidst harsh conditions. 

Choose the Right Rubber Compound

Select a rubber formulation designed to withstand the local climate. For example, EPDM or butyl rubber are typically ideal for outdoor use due to their UV, ozone, and temperature resistance.

Use Protective Coatings or Topcoats

Adding an external protective coating (like polyurethane or UV-resistant paint) can shield the rubber from sunlight and weather. These coatings also help resist mechanical abrasion and chemical attack.

Implement Regular Inspection and Maintenance

Routine visual inspections and spark testing can identify early signs of wear, cracking, or debonding. Inspections should be more frequent in climates with extreme temperatures or high moisture.

Avoid Water Traps and Promote Drainage

Ensure that the design of the tank or equipment promotes proper drainage. Pooled water or trapped moisture increases the risk of freeze/thaw damage and microbial growth.

Control Storage and Application Conditions

During rubber lining installation, temperature and humidity levels must be controlled to ensure proper bonding and curing. In-field repairs should be scheduled during favorable weather windows to avoid curing failures.

We’ll Help you Plan for Longevity, Regardless of Climate

Rubber linings are a reliable, long-term protective solution for industrial equipment, but only when matched to their environment. By understanding the threats and implementing smart strategies like proper material selection, protective coatings, and proactive maintenance, we can help you extend the life of your rubber-lined equipment.

Get started by contacting us for a consultation.

When it comes to protecting industrial tanks, you have options. Some facilities install rubber lining from day one to protect against corrosion or chemical attacks. Others look into lining later, when a tank starts showing signs of wear. Either way, one question always comes up when maintenance is due: Is it more cost-effective to line (or reline) the tank or just replace it?

The answer isn’t always obvious. Sure, a brand-new tank sounds nice, but it comes with a hefty price tag and often more downtime than expected. So in this article, we’ll break down the total cost of ownership between rubber lining or total tank replacement. We’ll look at upfront costs, maintenance, service life, downtime, and long-term value so you can plan ahead or deal with a current issue with confidence. 

Understanding Total Cost of Tank Ownership

Total cost of ownership (TCO) is a financial estimate that helps evaluate the direct and indirect costs associated with a product or system throughout its life cycle. In the context of industrial tanks, TCO can include:

• Initial purchase or repair cost
• Installation and labor
• Downtime during repair or replacement
• Ongoing maintenance
• Expected service life
• Performance and ROI

Upfront Cost Comparison: Tank Replacement vs. Rubber Lining

Tank Replacement: Replacing an entire tank requires significant capital investment, including:

• New tank fabrication (steel, concrete, or alloy)
• Freight and logistics
• Permitting and regulatory compliance
• Installation and foundation work
• Disposal of old equipment
  

Depending on size and material, replacement costs can run into the hundreds of thousands of dollars per tank.

Rubber Lining Installation: Rubber lining a tank costs a fraction of replacement, particularly for tanks where the shell is still structurally sound. Some expenses you might have are: 

• Surface preparation (blasting, cleaning)
• Rubber lining materials
• Installation labor
• Curing and inspection

Often at 40-70% less than replacement, rubber lining is more economical upfront to restore protection. An example scenario would be: a 10,000-gallon carbon steel tank costs ~$150,000 to replace, but can be relined for ~$50,000 using high-performance rubber lining.

Service Life & Durability

When properly applied and maintained, rubber linings can help tanks last 10–20 years or longer, depending on:

• Type of rubber used
• Service environment (temperature, pressure, chemical exposure)
• Application quality and curing process

Tank Maintenance and Inspection Requirements

Rubber lined tanks are: 

• Easier to inspect because the linings can be visually and spark-tested.
• Easier to repair because localized damage can usually be patched without relining the entire tank.
• Cheaper to maintain because there isn’t a need for recoating every few years like with some epoxy or paint coatings. 

New tanks (without rubber lining): 

• May require protective coatings anyway, especially for carbon steel.
• Offer great corrosion resistance but are much more expensive and can still suffer pitting or stress corrosion over time.

Downtime and Production Impact

One of the most important things to account for when making the decision between rubber lining and tank replacement is expected downtime. 

Tank replacement can take weeks or months because it requires decommissioning, demolition, site prep, installation, testing, and ramp-up. Each day offline can cost thousands in lost production.

Rubber lining installation can often be completed in a matter of days, especially by experienced crews. 

Total Cost of Ownership Comparison Chart

The Advantage of Rubber Lining Is Long-term ROI

While new tanks may last slightly longer in some cases, the cumulative cost savings of rubber lining — combined with faster return to service — typically results in a higher ROI over the tank’s lifespan.

Some additional benefits are: 

• Customization – Rubber lining can be tailored for chemical resistance, abrasion, or thermal stability.
• Sustainability – Relining extends the life of existing infrastructure, supporting any company-wide ESG goals. 
• Flexibility – Tanks can be relined again in the future, so you could delay full tank replacement sometimes indefinitely.

When Tank Replacement Does Make Sense

There are some situations where replacement may be the better long-term option. 

• Severe structural damage, like cracks or wall thinning, that rubber lining can’t help
• Significant deformation or pressure integrity issues
• Regulatory changes requiring full design updates

But for most corrosion or chemical wear cases, rubber lining is the more economical, lower-risk solution. 

Maximize ROI with Rubber Lining from US RUBBER

At US Rubber, our team specializes in rubber lining installation, repair, and NACE-certified inspection services for tanks, vessels, and piping systems. With decades of experience across industries — from chemical processing to water treatment — we help facility owners extend the life of their equipment, reduce costs, and improve safety.

Let’s work together to extend the life of your tanks without draining your capital.