Alexei Volkov
Plastic gas tanks are becoming increasingly common in vehicles. They are lightweight, flexible, and durable, and they do not corrode like metal tanks. In 2005, 29 PZEV-certified vehicles had metal gas tanks, but by 2025, 98% of all vehicles in Europe and 75% in the US had plastic tanks. Automakers have been switching to plastic tanks because they are easier to mould into the odd saddle shapes used in some vehicles. However, plastic tanks are not without their drawbacks. They are more expensive to manufacture and have been known to melt and fail in vehicle fires.
| Characteristics | Values |
|---|---|
| Vehicle Types | Cars, SUVs, Trucks |
| Vehicle Makes | Chevy, GMC, Ford, Jeep, Toyota, Chrysler, Dodge, IH Scout, International Harvester |
| Vehicle Models | 1984-1996 Jeep Cherokee XJ, 1984-1990 Jeep Wagoneer XJ, 2004-2018 Chevrolet Express, 1999-2003 Ford Super Duty F350, F450, F550, 1988-1996 Chevy, GM 1500, 2500 Pickup, 1982-1986 Chevy, GMC C10, C20, C30, K10, K20, K30 Pickup, 1973-1981 Full Size Chevy Blazer and Suburban, 1969-1975 International Harvester Pickup, Travelall, Travelette, Chrysler's LH series, Viper sports car, Dodge Ram |
| Gas Tank Material | Polyethylene, High-Density Cross-linking Polyethylene (HDPE), High-Density Polyethylene (HDPE) |
| Benefits | No welds or seams to fail or leak, No possibility of rust, Superior strength, Flexibility, Durability, Affordability, No corrosion, Recyclability, Lighter weight |
| Concerns | Melting and failure in vehicle fires, Stricter permeation standards, Higher manufacturing cost, Disposal and landfill issues |
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What You'll Learn
- Plastic gas tanks are more durable and affordable than metal tanks
- They are also more flexible and can be customised to fit any vehicle
- Plastic tanks are not susceptible to corrosion, unlike metal tanks
- However, plastic tanks will melt and fail when exposed to fire
- Automakers are moving towards plastic tanks to meet stricter emissions regulations
Plastic gas tanks are more durable and affordable than metal tanks
Plastic gas tanks are becoming increasingly popular, with 98% of vehicles in Europe and 75% in the United States opting for this choice. This shift towards plastic tanks is due to their durability and affordability compared to metal tanks. Firstly, plastic tanks are more durable because they are not susceptible to corrosion. All vehicles are exposed to corrosive elements on the road, such as salt, gravel, and debris, which can cause metal tanks to rust and corrode over time. Water vapours can also build up inside a metal tank, leading to rusting from the inside out. Plastic tanks, on the other hand, are inert to these corrosive elements and will not rust, ensuring a longer useful life.
Additionally, plastic tanks are more flexible and can be customized to fit specific spots in a vehicle's complex undercarriage. This versatility is advantageous for unique vehicle designs. Plastic tanks are also quieter due to the insulating properties of plastics, eliminating the sound of gasoline moving around.
In terms of affordability, plastic tanks are generally more cost-effective than metal tanks. Plastic is a less expensive material than steel, and plastic tanks are easier and cheaper to produce. While metal tanks may have a slightly lower upfront cost, plastic tanks can save money in the long run by avoiding the hidden costs associated with corrosion and rust. Steel tanks require regular cleaning, painting, and maintenance to prevent corrosion, whereas plastic tanks only need cleaning to remove debris and sediment.
Plastic tanks are also lightweight, making them easier to transport and install. This lightweight property also contributes to fuel efficiency, as plastic tanks reduce the overall weight of the vehicle, leading to better fuel economy. Furthermore, plastic tanks are more environmentally friendly due to their recyclability and lower carbon footprint.
While plastic tanks offer these advantages, it is important to consider the specific needs and regulations surrounding fuel tanks. Metal tanks have their own benefits, such as higher resistance to fire and explosions, making them ideal for certain industrial settings. However, plastic tanks are gaining popularity due to their durability, affordability, and ability to meet EPA regulations and increase vehicle efficiency.
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They are also more flexible and can be customised to fit any vehicle
Plastic gas tanks have become increasingly popular over the years, with 98% of vehicles in Europe and 75% in the United States adopting them. They offer several advantages over traditional metal tanks, including flexibility and customisation.
Plastic gas tanks, such as those made from polyethylene, are highly flexible. This flexibility allows them to be customised to fit any vehicle, regardless of the complexity of its undercarriage. Whether it's a Chevy, Ford, Jeep, Toyota, or IH Scout, plastic gas tanks can be tailored to the specific dimensions and requirements of each model.
One notable example of a company that offers customised plastic gas tanks is MTS. Over the last 30 years, MTS has expanded its range from a single CJ fuel tank to 80 different tanks compatible with various vehicles. Their tanks are designed with superior strength and durability in mind, utilising high-density, cross-linking polyethylene that is 1/4" thick. This material ensures that the tanks won't crack, leak, or rust, providing a reliable and long-lasting solution for vehicle owners.
In addition to MTS, other companies like Raybuck Autobody Parts, Miller Plastic Products, and Rotovia also specialise in custom plastic fuel tanks. These companies work closely with customers to design and manufacture tanks that meet their unique needs. Whether it's a specific shape, size, colour, or the integration of additional components like fuel level indicators or venting systems, these companies have the expertise and technology to deliver a tailor-made product.
The flexibility and customisation of plastic gas tanks are not only limited to their physical dimensions but also extend to their performance and functionality. For instance, Rotovia's rotomoulding technology enables them to create seamless tanks that are leak-proof and free of seams and joints. This not only enhances safety but also ensures that the tanks can withstand harsh conditions and heavy use.
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Plastic tanks are not susceptible to corrosion, unlike metal tanks
Plastic gas tanks are becoming increasingly common in vehicles. In 2025, 98% of all vehicles in Europe were outfitted with plastic gas tanks, and 75% of all vehicles in the United States. This is due to their flexibility, durability, and affordability. One of the key advantages of plastic tanks over metal tanks is their resistance to corrosion.
Metal tanks are susceptible to corrosion from the inside out due to water vapours that naturally build up when the tank is not completely full of fuel. Salt, gravel, and other debris from the road can also contribute to corrosion on metal tanks. Plastic tanks, on the other hand, are inert to corrosive environments, both inside and outside the tank. They do not require special coatings or treatments to prevent corrosion, saving time and maintenance costs.
The durability of plastic tanks has been questioned, with some arguing that they are more prone to physical damage, especially in harsh environments. Plastic tanks may degrade over time due to exposure to UV radiation and extreme temperatures, and they may not offer the same level of durability and longevity as metal tanks. However, plastic tanks are less likely to dent or deform and can maintain their shape over time.
In terms of cost, plastic tanks are generally more affordable than metal tanks, as they are less expensive to manufacture and transport. They are also lightweight, making them easier to install and handle, especially in limited-access areas or where there are weight restrictions.
Overall, plastic tanks offer a range of benefits over metal tanks, including resistance to corrosion, affordability, durability, and ease of installation. However, it is important to consider the specific requirements and limitations of each material when making a decision.
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However, plastic tanks will melt and fail when exposed to fire
Plastic gas tanks have become increasingly common in vehicles over the past few decades. They are used in many Chevy, GMC, Ford, Jeep, Toyota, and IH Scout vehicles. Chrysler's LH series and Viper sports car, as well as Dodge Ram trucks, also use plastic gas tanks. These tanks are made of high-density polyethylene (HDPE) and offer several advantages over metal tanks, including increased flexibility, durability, and resistance to corrosion and rust.
The vulnerability of plastic tanks to fire is a significant safety concern. Gasoline is highly flammable, and its vapors can easily ignite when exposed to heat or sparks, leading to explosions. Plastic gas tanks, when exposed to fire, can melt and cause gasoline to leak, creating a stream of burning gasoline that poses a severe risk to life, limb, and property. This scenario is a worst-case situation for firefighters, who may encounter challenges in extinguishing such fires.
To mitigate the risks associated with plastic gas tanks, manufacturers have developed multilayer tank technology. These tanks use a combination of materials, including HDPE, adhesive layers, barrier layers of polyamide or ethylene-vinyl alcohol copolymer, and "reground" layers, to enhance their strength and durability. However, multilayer plastic tanks are more expensive to manufacture and face recyclability challenges.
While plastic gas tanks offer benefits in terms of flexibility, durability, and corrosion resistance, their susceptibility to melting and failing in fires is a critical consideration. This limitation underscores the ongoing competition between plastic and metal tanks in the automotive industry, with metal tanks offering superior fire resistance.
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Automakers are moving towards plastic tanks to meet stricter emissions regulations
Automakers are increasingly adopting plastic tanks to meet stricter emissions regulations. This trend is driven by the need to reduce volatile organic compound (VOC) emissions from vehicles. Plastic tanks, made from high-density polyethylene (HDPE), offer several advantages over traditional metal tanks in terms of weight reduction, flexibility in design, and resistance to corrosion.
Plastic fuel tanks are typically 20% lighter than their steel counterparts, making them a favourable choice for automakers aiming to reduce vehicle weight and improve fuel efficiency. Additionally, plastic tanks can be customized to fit the unique shapes and spaces within a vehicle's undercarriage, enhancing their appeal for automakers.
One of the critical advantages of plastic tanks in meeting stricter emissions regulations is their ability to prevent the permeation of gasoline, a volatile organic compound (VOC). While HDPE alone may not sufficiently prevent gasoline permeation, the coextrusion of HDPE with other materials, such as SoarnoL™, creates an effective barrier against hydrocarbon permeation, thereby reducing VOC emissions.
Some manufacturers, such as Ford, have embraced multilayer tank technology to comply with stricter emissions standards. Ford utilizes six-layer fuel tanks made of HDPE, with additional layers of adhesive, polyamide or ethylene-vinyl alcohol copolymer, and "regrind." These multilayer tanks are designed to meet California's stringent evaporative fuel standards. However, the transition to plastic tanks has also faced challenges due to higher manufacturing costs and recyclability concerns, especially with multilayer tank designs.
While plastic tanks offer benefits in terms of weight reduction and emissions compliance, there are ongoing considerations regarding their long-term recyclability and environmental impact. As the automotive industry continues to navigate stricter emissions regulations, the development of plastic tanks showcases the innovative approaches automakers are adopting to balance performance, design, and environmental sustainability.
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Frequently asked questions
Many vehicles have plastic gas tanks. In 2005, 29 PZEV-certified vehicles had metal gas tanks, but by 2025, 98% of all vehicles in Europe and 75% of vehicles in the US had plastic gas tanks. Some vehicles with plastic gas tanks include:
- Ford Trucks
- Chevy Trucks
- Jeep
- Toyota
- Chrysler's LH series and Viper sports car
- Dodge Ram
Automakers have been moving toward plastic for fuel tanks because the material is lighter in weight and more flexible to mould into the odd saddle-shaped tanks used in some vehicles. Plastic gas tanks are also durable, affordable, and not susceptible to corrosion.
Plastic gas tanks will melt and fail when exposed to the high temperatures involved in a vehicle fire, whereas metal fuel tanks can resist high temperatures for greater periods. Plastic gas tanks also have higher manufacturing costs and recyclability issues.
