Tank validation testing
Hydrogen tanks must perform flawlessly under extreme pressure. Resato’s tank validation testing systems replicate real operating conditions to prove safety and reliability.
Each system delivers precise testing and supports compliance with standards such as R134 and GTR No. 13-2. This helps verify structural integrity, leak resistance and long term durability. Our technology enables safe hydrogen applications from early research to full scale production.
Want to know more? Read our blog about tank validation
Expert Support
Need help finding a specific solution tailored to your needs? Our team is ready to offer you advice customized to your requirements.
Built for extreme pressure performance
Our tank validation systems are engineered to handle the highest hydrogen pressures. They provide stable and precise testing even under the most demanding conditions.
Test benches can validate tanks up to 700 bar with test pressures reaching 1050 bar. By simulating real pressure cycles, the system supports safe performance throughout the tank’s lifecycle. This gives you reliable data for both development and certification processes.
Resato’s testing systems safely reach test pressures of up to 1050 bar.
Types of tanks your systems can be tested with
All-metal
steel or
aluminum
Steel or
aluminum
liner
Composite
hoop wrap
Steel or
aluminum
liner
Composite
full wrap
Plastic liner
Composite
full wrap
No liner
All-
composite
Resato’s testing methods
With our validation systems, you can test hydrogen tanks using both fluids and gases under controlled conditions. Cycle and burst testing allow for critical assessment during homologation and support reliable production batch testing. Our proof and leak test systems can be designed for use during homologation as well as for end-of-line testing within your production line. Together, these testing methods verify safety, durability, and structural integrity throughout the entire development and production lifecycle of your tanks. Our systems enable accurate, repeatable testing and deliver reliable data that complies with international certification standards.
Cycle Test
Cycle testing replicates the tank’s lifetime usage by simulating thousands of filling and emptying cycles (>15,000). This validates accurate measurement of leakage and pressure behaviour throughout the test sequence.
- -20°C up to 85 °C
- Fluids or gas
- Homologation testing
- Batch testing
Burst Test
A hydro burst test validates the tank’s safety margin and material strength through a controlled destructive test. To meet safety standards, a burst test must be performed for 0,5% of each produced batch.
- > 3000 bar
- Fluids
- Batch testing
Proof test
A proof test checks if a tank safely holds pressure during one controlled cycle. This confirms basic structural performance.
- > 1050 bar
- Fluids
- Homologation testing
- End-of-line testing
Leak test
Leak testing verifies whether a tank maintains stable pressure without measurable loss of gas. Controlled temperature conditions support accurate results and prevent external interference.
- > 875 bar
- End-of-line gas leak testing
- Gas leak permeation testing for homologation
How is safety guaranteed?
Hydrogen tanks operate under extreme pressure and therefore require reliable and secure testing systems. With our technology you can validate tanks safely and prevent failures in real applications. All systems meet CE requirements and include advanced features that protect operators during testing. Doorlocks, bunker setups and controlled environments help create a safe workspace for your team. These safeguards support accurate testing without exposing operators to unnecessary risk. Resato provides safe test systems and supports you with fully compliant testing environments.
Tailored solutions built around your application
Do you need a product or a solution?
Whether you're looking for a way to validate newly developed type IV tanks or facing limitations in efficiently testing the functional standards of your type II tanks during production, Resato's approach goes beyond simply selecting equipment. We analyse what you need.
Asking the right questions
What pressure ranges are you looking for? What standards do you have to comply with and what is your preferred level of automation? By addressing these types of questions, we collect the essential input to analyze your hydrogen tank testing challenge. This way, we are fully aligned from the start.
Identifying your technical challenges together
Together, we diagnose the bottlenecks in testing your hydrogen tanks, such as safety margins, compliance requirements or test efficiency. This ensures the solution supports reliable and repeatable validation and fits your needs.
Finding the right solution for you
Based on the defined requirements, we engineer a tank validation solution that meets your preferred standards and ensures full traceability. Integrated data acquisition software automatically records parameters and generates certification-ready documentation.
Building your solution made to last
Each tank validation system is designed to fit seamlessly into your facility, workflow and safety requirements. With service agreements, training and long-term support, we ensure reliable performance throughout the system lifecycle.
Interested in tank validation testing? Contact Resato
Are you looking for a reliable way to validate your hydrogen tanks? Resato provides high-pressure testing systems tailored to your application. Whether for Type 1 or Type 4 tanks, our experts will help you choose the right solution. Contact Resato for more information or get a custom solution. Our team is ready to offer you advice customized to your needs.
Our team is ready to offer you advice customized to your needs.