What to Do with a Leaking Air Compressor Tank: Repaired vs. Replaced

Any sort of leak in an air compressor tank requires immediate and thorough attention. A leaking air compressor can lead to reduced efficiency and performance, increased energy consumption, increased maintenance costs, etc. The list can actually go on for a while! 

The direct safety hazards are the most serious. If a 60-gallon air compressor tank with a maximum air pressure of 150 PSI suddenly bursts, the explosive air emission can be life-threatening. 

In addition to producing 140 dB sound (enough to rupture the eardrums), ≈ 680 mph air velocity can launch debris, shrapnel, and other metal fragments, causing serious injury to the people nearby. 

This raises an important question: Should you repair the leak in your air compressor tank or replace it immediately? We have the answer!

Here’s What You Do with a Leaking Air Compressor Tank

An air compressor tank can leak for several reasons. When equipment has issues, we usually have two options, repair or replacement. But is that really the case when you’re dealing with a leaking air compressor tank?

A leaking tank is often caused by cracks in welded seams or joint leaks. In such cases, replacement is usually the best option, as these cracks significantly weaken the tank’s structural integrity. Attempting repairs can sometimes make the situation worse, turning it into a losing battle.

Replacing the tank becomes a necessary step if the leaks result from corroded or rusted areas. A pinhole leak is a strong sign that the metal of the tank has thinned or weakened due to internal corrosion. 

The thing about internal corrosion is that it keeps going on, and the maintenance seems too much as it’s happening internally.

Epoxy or welding can be considered as temporary fixes, but gradually, you have to change it.  Because the corrosion will keep spreading day by day, and so will the risk of exploding under pressure. Better safe than sorry, right?

Many people choose to go with a temporary fix to run the machine for a few more days. Even though we strongly discourage that, we also feel the necessity to guide you through the process. 

First of all, hook the compressor tank and elevate it a little. Make sure the air pressure level is below the usual cut-in level. Spray soapy water thoroughly on the tank and mark the areas forming bubbles. Now, smoothen the area using sandpaper or a wire brush. 

Next, cover the hole with a temporary sealant such as JB Weld, epoxy, or any high-strength metal patch. Let it cure for a while so that the adhesive can fully bond and create a strong seal. 

Don’t forget that it’s just a temporary fix. You must replace and Find the best air compressor tank for your needs it as soon as possible. It can last a few days to a few months, but you never know when the catastrophe will happen from the leaking air compressor tank!

Final Thought

Deciding whether to repair a leaking air compressor tank or replace the complete unit depends on several aspects, such as the compressor’s age, the extent of the leak, repair cost, and whether the leak can be accessed easily. While a simple leak repair on a new compressor works well, it might not be too fruitful for an old one. 

Sometimes, the total repair costs are almost the same as buying a new one. That makes it quite easy to decide, but, in certain cases, you must replace one, even if it’s been just a few months. Sometimes you’re just unlucky, right? It’s not that hard to weigh the gains and losses if you think carefully.  

I’ve written this article based on knowledge of this topic, real-life experience in this regard, and well-thought-out research. Hope you found this helpful!