Client Background

A regional utility provider managing critical infrastructure for water treatment and distribution faced an urgent crisis when routine inspections revealed structural deterioration in multiple storage tanks. These tanks, essential for maintaining water pressure and supply to over 200,000 residents, showed signs of corrosion and stress fractures that posed immediate risks of catastrophic failure, potential environmental contamination, and regulatory violations.

The Challenge

The emergency tank reinforcement project presented multiple critical obstacles:

  • Immediate Response Required: Structural integrity degradation demanded mobilization within 72 hours to prevent catastrophic tank failure
  • Specialized Certification Requirements: Needed welders with dual expertise in structural repair welding and confined space entry certifications
  • Environmental and Regulatory Pressure: Risk of EPA violations and environmental contamination if tanks failed before repairs
  • Operational Continuity: Repairs needed completion without interrupting water service to residential and commercial customers
  • Safety Complexity: Work required in confined spaces with hazardous atmospheres and limited egress points

The Solution

Advastar mobilized a rapid-response welding team to address the crisis:

  • Immediate Deployment: Dispatched 8 certified welders within three days, pre-screened for structural repair and confined space credentials
  • Specialized Expertise: Provided welders experienced in API 653 tank repair standards and AWS D1.1 structural welding codes
  • Leak Repair Capabilities: Deployed specialists trained in hot tap and wet welding techniques for active leak mitigation
  • Reinforcement Welding: Executed plate overlays, seam repairs, and structural bracing to restore tank integrity
  • Safety Protocols: Implemented comprehensive confined space entry procedures with dedicated hole watch and atmospheric monitoring

The Outcome

Advastar’s emergency response delivered critical results for the utility provider:

  • On-Time Project Completion: All emergency repairs completed within the mandated timeline, preventing service disruptions
  • Financial Impact Mitigation: Prevented estimated $2.5 million in potential downtime costs and equipment replacement
  • Regulatory Compliance: Avoided EPA penalties and environmental violations through timely intervention
  • Zero Safety Incidents: Completed high-risk confined space work without any recordable injuries or near-misses
  • Long-Term Partnership: Client established Advastar as preferred emergency response partner for all future critical infrastructure repairs