Tanker plate and coil
Wide 5xxx plate and hot-rolled coil, typically 4 – 10 mm thick, in O, H111, H32 or H116 tempers. Wide plates reduce the number of longitudinal welds in the barrel.
Application guide · Road tankers
Aluminium for Tank Trucks and Tank Trailers
Road tankers for fuel, chemicals, asphalt and food liquids are built mostly from 5xxx aluminium-magnesium plate because it is light, tough, weldable and resistant to corrosion, so more payload can be carried on every trip. Shells, heads and baffles use 5083, 5182, 5454 or 5754 in O or H111 temper, with 6xxx profiles for frames and walkways and 5183 or 5356 filler for welding. This guide explains which alloy goes where, the standards that apply, and how to specify the materials.
- Shell alloys
- 5083 · 5182 · 5454 · 5754
- Tempers
- O, H111, H32
- Standards
- ADR 6.8 · EN 13094 · 49 CFR 178
- Filler
- ER5183 · ER5356
Why tankers are built from aluminium
A road tanker runs close to its gross weight limit on every loaded trip, so every kilogram saved on the tank is a kilogram of extra product. An aluminium tank barrel is typically far lighter than a carbon steel one of the same capacity, which is why aluminium has become the standard material for fuel tankers in Europe and many other markets.
The 5xxx alloys used for tank shells gain their strength from magnesium in solid solution rather than heat treatment, so they keep most of their strength after welding. They form a stable oxide film that resists petroleum products, many chemicals and road salt without paint, and they stay tough at low temperatures, so they do not become brittle in winter or in cryogenic service. Aluminium also does not spark when struck by steel tools in the way some metals can, and it is fully recyclable at the end of the vehicle's life.
Which aluminium alloy for each tanker part
| Component | Usual alloys and tempers | Why |
|---|---|---|
| Shell (barrel) plate | 5083-O/H111, 5182-O/H111, 5754-O/H111, 5454-O/H111 | Strength and elongation for the required equivalent thickness; good weldability |
| Heads (dished ends) and bulkheads | 5083-O, 5182-O, 5454-O | Annealed temper for deep forming without cracking |
| Baffles (surge plates) | 5083, 5754, 5052 | Formable plate that controls liquid surge |
| Asphalt and hot-product tanks | 5454-O/H111 | Magnesium below 3 % avoids sensitisation in service above about 65 °C |
| Walkways and platforms | 3003 or 5052 tread plate | Slip-resistant surface and good corrosion resistance |
| Sub-frames, ladders, rails, cabinets | 6061-T6, 6082-T6, 6063-T5/T6 extrusions | Extruded shapes for frames and fittings |
| Piping, vents and loading lines | 6061-T6, 6063-T6, 5083 tube | Light, corrosion-resistant tube and pipe |
| Flanges, manlid rings, fittings | 6061-T6 bar and forgings, 5083 plate | Machined parts that weld into the shell |
| Welding filler | ER5183, ER5356 | Matched strength and corrosion resistance for 5xxx plate |
Higher-strength tanker alloys such as 5059, 5088, 5186 and 5383 are produced by some mills to allow thinner shells. They are used where the tank design and approval specifically call for them.
Properties of the main tanker plate alloys
The table shows specified values for O/H111 plate in EN 485-2 for the thickness range used in tank shells. Limits change slightly with thickness band, so the mill certificate for each plate is the controlling document.
| Alloy (O / H111) | Tensile strength Rm | Yield strength Rp0.2 (min) | Mg content | Typical tanker role |
|---|---|---|---|---|
| 5083 | 275 – 350 MPa | 125 MPa | 4.0 – 4.9 % | Shells and heads for fuel, chemicals and LNG; highest common strength |
| 5182 | 255 – 315 MPa | 110 MPa | 4.0 – 5.0 % | Shells and heads; high elongation favoured for ADR equivalent thickness |
| 5454 | 215 – 285 MPa | 85 MPa | 2.4 – 3.0 % | Hot cargoes such as asphalt and some chemicals |
| 5754 | 190 – 240 MPa | 80 MPa | 2.6 – 3.6 % | Fuel and chemical tank shells, baffles and side plates |
Under ADR, the minimum shell thickness of an aluminium tank is derived from a reference steel thickness using a formula based on the product of tensile strength and elongation of the actual material (e₁ = 464·e₀ / ∛(Rm₁·A₁)²). That is why tank designers look closely at guaranteed elongation as well as strength, and why alloys combining both, such as 5083 and 5182, are popular for shells.
Standards and regulations for aluminium tankers
| Region / scope | Regulation or standard | What it covers |
|---|---|---|
| Europe and ADR countries | ADR Chapter 6.8 | Design, construction, approval and testing of tanks carrying dangerous goods by road |
| Tanks ≤ 0.5 bar working pressure | EN 13094 | Design and construction of metallic tanks, including aluminium fuel tankers |
| Pressure tanks | EN 14025 | Metallic pressure tanks for dangerous goods |
| Testing and inspection | EN 12972 | Testing, inspection and marking of metallic tanks |
| United States | 49 CFR 178.345 – 178.348 (DOT 406, 407, 412) | Cargo tank motor vehicle specifications; for ASME-code tanks, 178.345-2 lists 5052, 5086, 5154, 5254, 5454 and 5652 in O, H32 or H34 |
| Plate material | ASTM B209, EN 485, EN 573-3 | Chemistry, properties and tolerances of sheet and plate |
| Welding consumables | AWS A5.10, ISO 18273 | Aluminium filler wire and rod (ER5183, ER5356) |
The tank builder and the approval body decide which standard and alloy apply to a particular design. Material buyers should pass the full requirement, including temper, thickness tolerance and any elongation minimum, to the plate supplier so the certificate supports type approval.
Aluminium products for tanker building
Heads and circles
Plate blanks and circles for dished ends and bulkheads, cut to size for spinning or pressing.
Tread plate
3003 or 5052 checker plate for walkways, steps and platforms.
Extrusions
6061, 6082 and 6063 profiles for sub-frames, ladders, guard rails, hose trays and cabinets.
Tube and pipe
6061 and 6063 tube for vapour recovery, vents, loading arms and drainage; 5083 pipe for welded systems.
Bar, forgings and machined parts
6061 bar and forgings for flanges, manlid rings and fittings, machined to drawing on request.
Welding, forming and corrosion control
- Welding: MIG for long seams and TIG for fittings, with ER5183 for 5083 and other high-Mg plate and ER5356 for general 5xxx work. Remove the oxide by stainless brushing just before welding, keep plate and wire dry and clean, and use pure argon or argon-helium shielding to minimise porosity.
- Avoiding cracks: use O or H111 temper for heads and tight forming, keep bend radii generous, and avoid 4xxx (Al-Si) fillers on high-Mg plate, which can give weak, crack-prone welds.
- Hot service: alloys with more than about 3 % Mg (5083, 5182) can become sensitised to intergranular corrosion if held above about 65 °C for long periods; use 5454 for asphalt and heated cargoes.
- Dissimilar metals: isolate steel chassis, stainless fittings and copper items from the aluminium with insulating pads, sleeves and sealants to prevent galvanic corrosion.
- Cleaning: check that alkaline or acidic cleaning chemicals are compatible with aluminium; strong alkalis attack it.
- Inspection: radiography or ultrasonic testing of seams and hydrostatic or pneumatic testing of the finished tank as required by the code.
A typical aluminium fuel tanker material list
A typical multi-compartment fuel semi-trailer, built to ADR and EN 13094, might use the following materials. Actual thicknesses come from the design calculation and approval.
| Part | Material | Form |
|---|---|---|
| Barrel shell | 5083-H111 or 5182-O | Wide plate, 5 – 6 mm range |
| Heads and compartment bulkheads | 5083-O or 5182-O | Pressed or spun from plate blanks |
| Surge baffles | 5754 or 5083 | Plate, pressed with flanges and openings |
| Sub-frame and rails | 6082-T6 or 6061-T6 | Extruded profiles |
| Walkway | 3003 or 5052 | Tread plate |
| Piping and vapour lines | 6063-T6 or 6061-T6 | Extruded tube |
| Filler | ER5183 | MIG wire on spools |
References and standards
- UNECE – ADR, Agreement concerning the International Carriage of Dangerous Goods by Road (Chapter 6.8)
- 49 CFR 178.345-2 – Material and material thickness (cargo tank motor vehicles)
- EN 13094 – Tanks for the transport of dangerous goods: metallic tanks with a working pressure not exceeding 0.5 bar
- EN 485-2 – Aluminium sheet, strip and plate: mechanical properties
- ASTM B209 – Aluminum and Aluminum-Alloy Sheet and Plate
Aluminium (aluminum) for tank trucks: frequently asked questions
What aluminum alloy is used for fuel tankers?
Most fuel tanker shells and heads are 5083 or 5182 in O or H111 temper, with 5754 also common. 5454 is used for hot cargoes such as asphalt, and 6xxx extrusions for frames and fittings.
Why is 5454 used for asphalt tankers?
Its magnesium content is below 3 %, so it does not become sensitised to intergranular corrosion when held at elevated temperature, unlike 5083 or 5182.
Which filler wire should be used for tanker welding?
ER5183 for 5083, 5182 and other high-magnesium plate where weld strength matters, and ER5356 for general 5xxx welding. Avoid 4043 on high-Mg alloys.
Is aluminium allowed for dangerous goods tanks under ADR?
Yes. ADR Chapter 6.8 allows aluminium alloy tanks, with minimum shell thickness calculated from the material's strength and elongation, and EN 13094 covers the design of low-pressure metallic tanks including aluminium.
What thickness of plate is used for tank shells?
Shell thickness comes from the design calculation and approval; for road fuel tankers it is commonly in the 4 – 8 mm range, with heads sometimes thicker.
Can Metline supply all the aluminium for a tanker build?
Yes. Metline supplies 5xxx plate and coil, tread plate, 6xxx profiles, tube, bar and welding wire to tanker builders worldwide, with EN 10204 3.1 certificates and export packing.
Building tank trucks or trailers?
Send your alloy, temper, plate sizes and the approval standard. Our team will reply with availability, certification and a delivered price.
