Permastore Construction Guide

CONSTRUCTION GUIDE for TANKS AND SILOS These are guidance notes that cover the mechanics of the various tasks detailed. They only refer to issues directly directly connected connected with with the execution execution of the works. works. Only authorised authorised persons/contractors adequately supervised, correctly equipped and trained in all aspects of the risks involved and the equipment to be used should be employed to carry out this work. They must also be familiar with the safety data sheets of all products used. It is the responsibility of the person/contractor undertaking these works to consider each particular installation, its environment and the specific risks involved. Whilst every care has been taken to ensure the accuracy of this guide through 1 May 2010, Permastore shall have no liability for any loss or damage (direct, indirect, special or consequential) consequential) arising out of or in connection connection with this guide. guide. This guide is subject to supplementation supplementation or change at any time time without notice at Permastore's Permastore's sole discretion. discretion. This guide does not constitute a representation or warranty of any kind in favour of the customer, and the customer's sole warranty is that which is provided in its sales contract with the distributor. This guide does not amend amend or change such sales contract contract in any way. way.

Permastore Limited Eye, Suffolk, IP23 7HS, England Tel : +44 (0) 1379 870723 Fax : +44 (0) 1379 870530 E-mail : [email protected] Doc Ref: P132 Rev 9

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Permastore Construction Guide

LIST OF CONTENTS PART

SECTION

TITLE

PAGE

FOREWORD

3-6

One

1

General System Description Descripti on

7-8

One

2

Tools and Equipment Equipment

9-11

One

3

Planning

12-14

One

4

General Construction Information Information

15-19

One

5

Sheet Identification

20-21

One

6

Standard Sealants, Cleaners and Primers

22-23

One

7

Applications Requiring the use of Silicone Sealants

24-25

One

8

Tank Fixing Details

26-28

One

9

Structure Dimensions

29-30

Two

1

Foundation Design and Sealing Options

31-34

Two

2

Clamping and Levelling Systems

35-36

Three

1

Assembly of Tanks From the Base Up

37-39

Four

1

Assembly of Tanks Using Jacks

40-45

Four

2

Assembly of Tanks Using Jacks and Starter Ring

46-47

Four

3

Assembly of Double Skin Tank Sheets

48-50

Five

1

Annular Tanks

51-52

Five

2

Backfilled Tanks

53-56

Six

1

Roof Construction Introduction

57-58

Six

2

Trough Deck Roof Construction

59-60

Six

3

20° Stainless Steel Roof Construction

61-63

Six

4

External Tapered Beam Roof Construction

64-65

Six

5

External Parallel Beam Roof Construction

66-68

Six

6

GRP Roof Construction

69-70

Six

7

Pressure Testing of Roofs

71-72

Seven

1

Glass-Fused-to-Steel Glass-Fused-to-Steel Floors

73-75

Eight

1

Cones

76-79

Nine

1

Ancillaries

80-89

Ten

1

Checklist

90-91

Ten

2

Low Voltage Testing

92-93

Eleven

1

Troubleshooting

94-97

Pictures from Tools List in Part One Section 2

A1-A4

Appendix A

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LIST OF CONTENTS PART

SECTION

TITLE

PAGE

FOREWORD

3-6

One

1

General System Description Descripti on

7-8

One

2

Tools and Equipment Equipment

9-11

One

3

Planning

12-14

One

4

General Construction Information Information

15-19

One

5


20-21

One

6

Standard Sealants, Cleaners and Primers

22-23

One

7

Applications Requiring the use of Silicone Sealants

24-25

One

8

Tank Fixing Details

26-28

One

9


29-30

Two

1


31-34

Two

2

Clamping and Levelling Systems

35-36

Three

1

Assembly of Tanks From the Base Up

37-39

Four

1

Assembly of Tanks Using Jacks

40-45

Four

2

Assembly of Tanks Using Jacks and Starter Ring

46-47

Four

3


48-50

Five

1

Annular Tanks

51-52

Five

2

Backfilled Tanks

53-56

Six

1

Roof Construction Introduction

57-58

Six

2


59-60

Six

3


61-63

Six

4


64-65

Six

5


66-68

Six

6

GRP Roof Construction

69-70

Six

7


71-72

Seven

1

Glass-Fused-to-Steel Glass-Fused-to-Steel Floors

73-75

Eight

1

Cones

76-79

Nine

1

Ancillaries

80-89

Ten

1

Checklist

90-91

Ten

2

Low Voltage Testing

92-93

Eleven

1

Troubleshooting

94-97

Pictures from Tools List in Part One Section 2

A1-A4

Appendix A

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FOREWORD

This Construction Guide is provided by Permastore Limited for its Distributors/Contractors. Distributors/Contractors are advised to study this guide thoroughly and ensure that their building crews are properly trained to use the information provided. Distributors/Contractors are contractually responsible to their customers for the quality construction of the as built structure.

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Foreword

This Construction Guide is intended as a quick reference manual for experienced crews trained by Permastore. It is not intended as a do-it-yourself manual by end users, as it does not included step-bystep instructions for assembly, installation or commissioning. The Guide is correct at the time of going to press. In the event of any doubt concerning any technical point, please contact the Sales Office at Permastore.

c)

Do not swallow chemicals and do not use them in areas where food is consumed. If any chemicals are ingested, refer to safety data sheets and seek medical assistance immediately. Make sure that chemical products are kept and used out of the reach of children and animals.

d)

Do not smoke in areas where chemical products are used, as many of them are flammable.

e)

Do not inhale chemical vapours or dust. Use a suitable mask and ensure that the workplace is adequately ventilated. Vapours from solvent-based products may have a cumulative effect over time; they also tend to build up in enclosed spaces. In the event of any symptoms, leave the work area immediately and move into fresh air. If the symptoms persist refer to safety data sheets and seek medical assistance.

f)

Ensure that there are adequate facilities for washing and cleansing the skin and that appropriate cleansers and barrier creams are available.

g)

Store chemicals in sealed containers in well ventilated areas and out of the reach of children. Do not transfer chemicals from one container into another unless such action is called for by the process.

h)

Clean up all spillages immediately.

i)

Except for transport in closed packages or sealed containers, chemical products should be handled only by authorised personnel.

j)

Ensure that the correct equipment is available for handling the chemical products provided.

k)

If any person handling the chemical products on the site shows symptoms which may be caused by exposure to the products, remove the person from the site, refer to safety data sheets and seek medical advice.

Health and Safety Requirements

All work described in this guide must be carried out in accordance with all relevant local health and safety regulations. In the United Kingdom the Health and Safety at Work Act 1974 applies. The requirements for training and instruction of work crews are covered by Section 2 of this Act. Regulation 3 of the Management of Health and Safety at Work Regulations 1992 requires a risk assessment to be carried out at all sites prior to commencement of work. Irrespective of legal requirements, always observe the following health and safety rules:1.

The Safe Handling of Chemical Products

The chemical products (sealants, primers, cleaners, etc) needed for the construction of PERMASTORE ® tanks and silos must be handled only by experienced personnel, who should be adequately supervised by their employer to ensure that all work is carried out in a safe and correct manner. Always observe the following points:a)

b)

Read the manufacturer's instructions on the container or accompanying safety data sheet before starting to use the product. Chemical products must never be allowed to come into contact with eyes or skin. Always wear appropriate protective clothing and eye protectors. Use a barrier cream on your hands and generally observe good industrial hygiene practices. Remove splashes with an industrial hand cleanser, never use cleaners or solvents to remove splashes from skin. Persons vary in their sensitivity to different chemicals. Some persons react to trace chemicals from splashes on outer clothing; ensure that clothing is properly laundered. In the event of irritation, burns or other symptoms, refer to safety data sheets and seek medical assistance.

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2.

Fire and Explosion Risk

Some of the products used on site are flammable. Vapours given off by some products, when mixed with air, may be explosive. Therefore:a)

Never use naked flames in the work area.

b)

Do not smoke in the work area.

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c)

Foreword

Avoid the use of spark-producing equipment (electric switchgear, grinders, etc) in the work area.

Never dispose of surplus sealants or cleaners into the drains; ensure their safe removal in accordance with regulations for the safe disposal of industrial waste. If primer or cleaner are spilled, soak up the spillage with dry sand, scoop the sand into strong polythene bags and dispose of them in accordance with regulations for the safe disposal of industrial waste.

d) Never use water as an extinguishant. Use CO² extinguishers or dry powder extinguishers. e)

f) 3.

Ensure good ventilation in the work area and keep chemical product containers sealed when not in use. Store all flammable materials in accordance with the relevant safety regulations.

Handling Hints

Chemical products used on site may have a limited shelf life, which is dependent on storage temperature. Do not order these products prematurely, to avoid deterioration. They should be stored in areas which are cool, dry, well ventilated and secure. Refer to the manufacturer's instructions or accompanying safety data sheet. Sealants: Can burn if subjected to intense heat or direct flames. To extinguish burning sealant, use CO²/foam or dry powder extinguisher.

Remove splashes of sealant on skin immediately with an industrial hand cleanser. Sealants normally present no inhalation problems given good ventilation. Scrape up spilled sealant or drips from excessive application, then wash the area affected with a strong industrial detergent in hot water. Primers and Cleaners: Contain solvents and are flammable. Use them only in well ventilated areas.

Do not smoke when using them and keep away from all naked flames, intense heat or sparking equipment. To extinguish a fire use CO²/foam or dry powder extinguisher or, in an emergency, dry sand or earth. Remove splashes on the skin with an industrial hand cleanser. Dry the skin with disposable paper towels, not with a cloth towel. Solvent vapours, even under conditions of low rates of evaporation, can quickly build up in enclosed areas lacking adequate ventilation. Wear a suitable air mask. If you feel drowsy, nauseous or if you experience breathing difficulties, move into fresh air.

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4.

Site Safety

All relevant site safety regulations must be observed. In general, these would include the following requirements:a)

Wear appropriate safety clothing, including helmets, masks, goggles, ear protectors, coveralls, gloves and safety boots.

b)

For work above ground level, use approved safety harness.

c)

Secure all ladders at the top. In some cases it may also need to be restrained by an assistant. If a ladder is not secured and not in use, it must be laid down.

d)

Scaffolding must be erected in the approved manner and secured during use. When not in use, scaffolding must be left secure and with all means of access removed.

e)

All hand held electric tools and equipment should be of 110v type.

f)

All plant and electric equipment must be inspected at regular intervals and faults must be repaired before further use.

g)

Every installation crew must be provided with a first-aid kit as standard equipment.

h)

Personnel working on sewage treatment plants must be protected against leptospiral jaundice. Infection is usually via broken skin or cuts, which must therefore be properly protected. All personnel must be issued with and must always carry a special card containing details of their occupation, the name of their doctor and precautions to be taken against leptospiral jaundice. This card must be produced when a visit is made to a doctor or hospital and those in attendance must be made aware of the holder's occupation.

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i)

5.

Foreword

Special precautions, such as the provision of forced ventilation and lifting harness, must be taken to safeguard personnel working within a structure which has been classified as a 'confined space'.

Site Practice

To ensure that all work is carried out to the required standard of quality, observe the following rules:a) Tank kits are shrink-wrapped prior to shipment; they should not be accepted for delivery to the site more than 4-6 weeks before commencement of installation. b) Store kits off the ground and clear of any surface water. Avoid storing kits in busy areas where they may suffer damage. c) Whenever possible, transport the sheets to the tank site on their original packing skids. Use care when lifting sheets off the stack. d) Keep the storage time of sealants to a minimum, as they have a limited shelf life, especially at high ambient temperatures. 6.

Safety Awareness Signage

All Safety Awareness signage provided within the tank construction kit must be installed at low level in close proximity to entry/access equipment (eg Access Hatch, Ladder, Staircase, Walkway etc) ensuring that those who need to enter or access the structure for inspection or maintenance purposes are made aware of any potential dangers.

not fully conversant with these requirements must contact his local Health and Safety Advisory Board for assistance. While every care has been taken to ensure the accuracy of this guide up to the date of publication, Permastore shall have no liability for any loss or damage (direct, indirect, special or consequential) arising out of or in connection with this guide. This guide is subject to additions, deletions or changes at any time without prior notice at the sole discretion of Permastore. This guide does not constitute a representation of warranty of any kind in favour of the customer. The customer's sole warranty is that which is provided in the customer's sales contract with the distributor of Permastore products. This guide does not amend, change or supersede such sales contract in any way. Registered Trade Names and Copyright

The following trade names, PERMASTORE ®, ® FUSION®, ISOFUSION® V700, HV ISOFUSION , TRIFUSION®, ECOFUSION®, TRIFUSION® PLUS and Fusion Tanks & Silos are the property of Permastore Limited. Permastore Limited reserves all copyright in this guide. Neither the complete guide nor any part of it may be used without prior permission for any purpose other than the purpose for which it is issued by Permastore.

About This Guide

Where necessary, comments on three levels have been added to the instructions:NOTE: Denotes information of a general or technical nature which may be found helpful. CAUTION: Draws attention to actions which may cause damage to equipment or materials. WARNING: Highlights risks of accidents or injury to personnel.

The instructions and notes are intended primarily as a guide for the proper construction of Permastore tanks and silos. The cautions and warnings, as well as the general safety and health rules above, are provided in the interests of safety. Any person in control of a construction project or responsible for site safety in any other capacity must comply fully with all national and local safety laws and regulations; any such person Doc Ref: P132 Rev 9

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PART ONE – Section 1 General System Description

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General System Description

The Permastore product is a bolted modular system for the construction of tanks, silos and similar steel structures of essentially regular cylindrical form of diameters from 3.41m to 85.38m (11ft-280ft) and heights from 1.4m to 29.4m (5ft-96ft) dependent upon the diameter. Capacities range from 13m3 to over 36,000m3 (2,860gals – 7,920,000 gals).

holes. Since each hole must be slightly larger than the bolt to facilitate assembly, all bolts must be in shear between sheets when they are tightened. Hence the importance of ensuring the correct straight shank length is used. See Part One: Section 7.

The system comprises essentially high-grade steel sheets, silo bolts, roof beams and panels, stiffening and fixing members, as well as a wide range of ancillaries (manholes, flanges, launders, ladders, platforms, etc). The steel sheets, which are rollcurved to the radius appropriate for any given application, are punched with one or several rows of holes, through which they are bolted t ogether on site. The sheets are coated on both sides by a special Glass-Fused-to-Steel vitreous enamelling process for which the trade names ECOFUSION , ® ISOFUSION V700, HV ISOFUSION®, TRIFUSION® and TRIFUSION® PLUS are used. This FUSION® family of vitreous enamel provides cost effective storage solutions in applications from the storage of agricultural sludges to very demanding municipal/industrial effluents. The coating is sprayed and fused onto the specially prepared sheets at the Permastore plant. Sheets are tested to confirm continuity of the Glass-Fused-toSteel vitreous enamel coating. For protection during transport and storage the edges are coated with an anti corrosive system.

Where tanks are provided with Glass-Fused-to-Steel vitreous enamel floors strict supervision is called for during construction of the floor and any further work. The floor should be temporarily protected from damage which may be caused by footwear and careless handling of tools. Following completion of construction the structure should be swab tested to confirm the continuity of the internal Glass-Fused-to-Steel vitreous enamel coating. See Part Ten: Section 2 of this guide. The application of this test must be witnessed by the customers site representative following which the 'On Site Wet Swab Testing Results Chart' (Doc Ref: 02.04.02 Appendix 7) and the 'Certificate of Completion' (Doc Ref: 02.04.02 Appendix 4) must be authorised by the Sub-contractor and the customer's representative. All tanks, silos and similar storage and process vessels are subject to containment and environmental stresses. Each unit is carefully designed to give reliable performance. You must therefore ensure that the methods of construction as detailed in this guide are carefully followed. In case of doubt, don't guess; ask your employer for clarification.

The overlap between sheets (both horizontal and vertical) must be coated with sufficient sealant for enough to be squeezed out when the bolts are tightened to allow it to be smoothed into a fillet which covers the edge of the sheet and extends several millimetres onto the exposed side of the sheet. Similarly, bolts and holes must have sufficient sealant to protect the bore and the shank, and to squeeze out to form a seal around the bolt head and nut. A bead of sealant must also be used to seal the nut when plastic nut covers are utilised. The proper application of sealant is absolutely essential for making the tank leakproof. Strict supervision of the sealing operation can save you a lot of trouble after completion and testing, when any leaks will have to be made good. Another point calling for special attention is the proper expansion of vertical sheet joints. Although tanks are nominally straight-sided, each ring (horizontal course of sheets) is slightly tapered inward, so that the outer face of one ring can fit against the inner face of the ring below it. The slight taper is achieved by the appropriate location of the Doc Ref: P132 Rev 9

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PART ONE – Section 2 Tools and Equipment

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Permastore Construction Guide SMALL TOOLS AND EQUIPMENT ERECTION AND TESTING

Tools and Equipment FOR

The following schedule of small tools is our recommendation for a single construction crew:1.

Levelling instrument accurate to within 1.5mm (1/16 inch) – (recommend Dumpy or laser level). – See Appendix A Picture No: 1.

26. Plastic floats x 2. See Appendix A Picture No: 7. 27. Bolt croppers.

2.

Large tape measure capable of measuring radius of tank.

28. Small tape measure – 5m (15ft).

3.

Ratchet spanner.

29. Polyester slings for moving skids and lifting sheets.

4.

19mm (¾ inch) A/F impact sockets x 4 (heavy duty).

5.

Tapered podgers to align holes in sheet, 3mm (1/8 inch) tapered up to 14mm (9/16 inch) (recommend Britool pry bars No 219 x 4). See Appendix A Picture No: 2.

6.

Cold chisel.

7.

Spanner set (open end and ring).

8.

Screwdriver set.

9.

Putty knife x 8.

reamer.

See

31. 300mm (12 inch) adjustable spanner. 32. Stilsons. See Appendix A Picture No: 9. 33. 220mm (9 inch) cutting discs x 4. 34. Safety glasses. See Appendix A Picture No: 12. 35. Ear protectors. See Appendix A Picture No 10. 36. Safety helmets. See Appendix A Picture No 11. 37. Safety harness. See Appendix A Picture No 13.

10. Hacksaw and blades. 11. 1m (3ft) spirit level. See Appendix A Picture No: 3. 12. Lifting hooks for carrying shell sheets. Appendix A Picture No: 4.

30. 12.5mm (½ inch) bridge Appendix A Picture No: 8.

See

38. Gloves – good supply. See Appendix A Picture No 14. 39. Wheelbarrow x 2. 40. Large special socket ½ inch drive for anchor bolts.

13. Sheet plate carrier.

41. Cleaning cloths.

14. Centre punch.

42. Selection of drill bits 3mm (⅛ inch) to 13mm (½ inch).

15. Crowbar 3ft long. 16. Hammer – ball peign. 17. Torque wrench to cover range from 14Nm (10ft-lb) to 70Nm (50ft-lb). See Appendix A Picture No: 5.

43. Wet sponge continuity detector – Elcometer model 269. See Appendix A Picture No 16. 44. Aluminium mobile scaffold tower. 45. Sealant trowels x 2.

18. Plastic bucket x 6.

46. One set of Allen keys.

19. Marker pens and chalk.

47. String line

20. Mole grips. See Appendix A Picture No: 6.

48. Lock-up tool chest to be kept on site.

21. Tin snips.

49. 2 x 10mm (⅜ inc h) shackles.

22. Pliers. 23. Scissors. 24. Broom. 25. Shovels x 2.

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Tools and Equipment

ELECTRICAL EQUIPMENT (ALL 110 VOLTS) 1.

Impact gun ½ inch drive – Bosch, Makita, Dewalt or similar. See Appendix A Picture No: 15

2.

Extension lead – length suitable for site.

3.

Power drill. See Appendix A Picture No: 17.

4.

220mm (9 inch) disc grinder.

5.

Electrical hoist for lifting sheets.

6.

Jig-saw – recommend Bosch variable speed (if holes are to be cut in tank plates) with a selection of blades to suit above, Bosch type T118B. See Appendix A Picture No: 18.

7.

Mobile generator if mains power is not available for 110v electric tools. See Appendix A Picture No: 21.

8.

HILTI Hammer Drill plus drill bits to install anchor bolts.

9.

Single phase 110v Transformer.

LARGE EQUIPMENT FOR SPECIFIC APPLICATIONS 1.

Concrete vibrator for rebate concrete. Appendix A Pictures No: 19 & 20.

2.

Small crane, or similar, for the installation of sheets for tanks 2 rings high and above and for positioning pallets of sheets strategically around the tank when construction jacks are the preferred solution.

3.

Crane to lift roof beams and centre support rings.

4.

Construction Jacks are recommended for the construction of tanks/silos with roofs and/or 2 rings high and above. (Contact Permastore for further advice on suitability and usage).

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See

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PART ONE

Section 3

Planning

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Planning

PLANNING

ON ARRIVAL AT SITE

1.

1.

The distributor/contractor should commission a soil load-bearing test by a qualified soil test engineer. Copies of the certificate should be given to:-

The Crew Leader Should:a)

Make contact with the customer and jointly inspect the site location to ensure that there are no obvious safety hazards (eg overhead power cables etc) and that clear access is available for delivery vehicles and construction equipment.

The original certificate should be retained in the distributor/contractor project file.

b)

Study the site plan and soil load- bearing certificate.

2.

When planning the site layout the customer's future plans should be taken into account as this could affect the positioning.

c)

3.

A site plan must be drawn, agreed and signed by the customer to safeguard against any possible changes being requested after the installation commences.

Ensure that the distributor/contractor has ordered necessary materials. Remember that materials are not always available at short notice.

d)

The distributor/contractor should ensure the availability of the tools and equipment list in Section 2 of this guide.

Mark out the site and obtain the customer's signature on the site plan. Do not commence operations without this signature unless you already have a signed copy.

e)

Place and fix a centre post, if installing foundation/bases.

f)

Check with the distributor/contractor about soil disposal and who is responsible for it.

g)

Supervise the digging of the foundation footings, placement of levelling stakes and reinforcing.

4.

5.

6.

a)

The construction team/crew leader.

b)

The customer.

The distributor/contractor should appoint a suitably qualified construction team and also ensure that all plant and materials required will be on site when required. One suitably trained person from the construction team should be made crew leader. The crew leader should be responsible at all times for the safe working practices of the crew operation, as well as ensuring safe site conditions, correct sequence of work and coordination in general. a)

The Remaining Crew Members Should:a)

Make a thorough check of the parts box and sheet pallets against the packing list provided and report any shortages immediately to the crew leader. The distributor/contractor should immediately report any shortages so as to prevent delays at a later stage of the construction.

b)

Do sub-assembly work on ladders and platform.

The crew leader should: i)

ii)

liaise with the distributor/contractor to ensure the arrival of plant and materials; liaise with the customer to discuss the site plan and safe site working with respect to other sub-contractors and normal site operations;

iii) set a good example to the other members of the crew. b)

2.

The crew leader must also be capable of reading site plans and drawings, and be conversant with all aspects of erection work.

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3.

During Construction Supervision checks should be made:a)

After excavation work is complete and before pouring concrete, should there be any indication of the presence of organic matter such as rotting vegetation or other foreign objects, work should cease and expert advice sought.

b)

To check the approved drawings footings and base dimensions, anchor bolt, structure bolt positions and any other relevant measurements. Page 13 of 97


4.

Planning

c)

Where construction of the tank is on a previously prepared concrete foundation by others, the centre point and orientation datum's must be marked by the customer or his representative.

d)

After the base ring is complete and before pouring concrete, the base ring should conform with the specified levels, concentricity (fit top angle temporarily) and be clamped securely.

e)

Following or during construction the internal Glass-Fused-to-Steel coating should be checked in the presence of the customer's representative to ensure continuity. Part Ten : Section 2 of this guide refers.

After Structure Completion

The structure must be inspected by the distributor/contractor or his delegated competent representative in accordance with the specifications detailed herein. Refer to the Permastore Inspection and Maintenance Manual Document Reference P110, as well as Part Eleven of this guide.

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PART ONE – Section 4 General Construction Information

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General Construction Information

GENERAL CONSTRUCTION INFORMATION 1.

3.

CAUTION: Take care that objects are not dropped onto any Glass-Fused-to-Steel Glass-Fused-to-Steel sheets.

4.

Tanks are assembled using 12.5mm (½ inch) bolts within 14mm (9/16 inch) holes. It is important that all vertical joints are fully expanded during construction to prevent movement movement under full hydraulic load, failure to do this can cause leaks and deformed vertical seams.

5.

For tank sheets above 10mm thick, fully expanded vertical joints using a tank sheet hydraulic joint expander expander assembly. assembly. A sheet joint expander kit is available from Permastore.

6.

When building tanks from the base up it is easier to assemble rings of sheets working clockwise.

7.

CAUTION

Sheet surfaces must be clean and dry when sealant is being applied. See Note 2 under 'Standard Sealants and Primers Primers Part 1 Section 6. Sealant must always be spread to cover the total area of the overlap to ensure correct sealing.

2.

CAUTION: Glass-Fused-to-Steel sheets will bend to a natural tolerance but special care should be taken when handling.

Bolts should be tightened to a torque of 65Nm (46ft-lb) except through tapered inserts, which should be tightened to a torque of 32Nm (23ft-lb). Failure to conform to this standard may cause damage to the panels. 8.

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It is essential that the correct length bolts are used in the correct place during construction. Always check fixings charts for the bolt sizes to be used. 9.

Before inserting the structure bolts, ensure sealant has been applied into and around each bolt hole as a safeguard safeguard against against leaks.

12. All ancillary items bolted to Glass-Fused-toSteel sheets such as angles and brackets must be fully coated with sealant on contact surfaces to prevent leakage. leakage. 13. All levels must always be maintained at + or – 1.5mm (1/16 inch).

10. It is essential to fillet all sheet edges, vertical and horizontal, both inside and outside the structure.

Wherever possible levels should be checked from within the structure.

11. At all points where an angle overlaps a vertical joint, tapered inserts inserts must be used. used.

14. The circularity on all structures must be to the following standards:Diameter

Circularity

Up to 13.7m (45ft)

± 6mm (¼ inch)

From 14.5m to 26.5m (48ft to 87ft)

± 12.5mm (½ inch)

27.3m above

± 25mm (1 inch)

(90ft)

and

Refer to Part One – Section 8 for structure diameters.

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15. The vertical joint and corner assembly arrangements for each vertical Series 1400 sheet joint interchanges are shown as follows, the individual drawings show the sheet relationship and the general view shows an 'as-built' typical example when viewed from the exterior of the structure.

16. Sheet identification stickers, which are placed near a vertical seam overlap joint, should be removed before applying sealant. 17. The length of the bolts can be determined by the colour of the plastic coating on the bolt heads:-

The plastic capped bolt head is always used on the inside of the structure. Standard Bolts:Colour

Black Grey Blue White Red Green

Length (mm) 25 32 38 44 51 64

Length (inches) 1 1¼ 1½ 1¾ 2 2½

Length (mm) 51 64 76

Length (inches) 2 2½ 3

Special Bolts:Colour

Brown Mauve Yellow Doc Ref: P132 Rev 9

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17. CAUTION: If Glass-Fused-to-Steel panels require cutting on site the operation must always be carried out using a jig-saw type cutter (refer to Part Eleven – Section 1).

19. CAUTION: Do not attempt to cut Permastore sheets with a mechanical grinder or use on other parts in the locality of Glass-Fused-to-Steel where sparks may contact and adhere to the surface.

18. CAUTION: Do not attempt to cut Permastore sheets with gas cutting equipment or use on other parts in the locality of Glass-Fused-to-Steel, where sparks may contact and adhere to the surface.

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PART ONE – Section 5 Sheet Identification

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SHEET IDENTIFICATION

MATERIAL IDENTIFICATION EXAMPLES

The sheet identification system (ID holes) is visible externally after construction and the ID piercing provides a clear indication of sheet thickness, steel grade and sheet taper. MATERIAL IDENTIFICATION

Four different hole shapes indicate the grade of steel:-

TAPER IDENTIFICATION

In order to ensure trouble free sheet to sheet assembly, Series 1400 sheets are produced with a slight taper to accommodate the horizontal overlap. Dependent on the sheet thickness and tank diameter one of the following options will be provided. The absence of any notch would signify a straight sheet with no taper. MATERIAL THICKNESS IDENTIFICATION

To indicate the sheet thickness the standard horizontal bolt holes are used as datum points.

Notch 1 Notch 1 & 2 Notch 1, 2 & 3 Notch 1, 2, 3 & 4

= Taper Reference 14t = Taper Reference 38t = Taper Reference 62t = Taper Reference 86t

"Whole numbers" ie 2mm, 3mm, 4mm etc are positioned 40mm to the right of the datum point and the "half numbers" ie 2.5mm, 3.5mm etc are positioned 40mm to the left of the next datum point. For examples refer to the drawing.

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PART ONE – Section 6 Standard Sealants, Cleaners and Primers

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STANDARD PRIMERS

SEALANTS,

CLEANERS

Sealants and Primers

AND

The following list of sealants and ancillary products represents those most commonly used for t he standard range of applications. Sealant Colour

The standard utilisation policy for the construction of all dark coloured tanks, including standard blue and green tanks, is to use Sikaflex TS Plus Black sealant. For all light shades of colour including white, grey and desert tan tanks Sikaflex TS Plus Grey sealant will be utilised.

NOTE 2: It is recommended practice for GlassFused-to-Steel surfaces to be clean and dry prior to the application of the sealant. Glass-Fused-to-Steel panels are wrapped after manufacture to ensure that they are clean and dry at the time of construction. When it is necessary to clean the surface use Sika Cleaner 205 or alternatively, pure xylene, methylethylketone (MEK) or isopropylalcohol (IPA). Do not use any solvents or cleaners that might leave a residue or contain turpentine, white spirits, phenols, organic acids, surfactants or silicones. If in doubt check with Permastore prior to use.

Sikaflex TS Plus

Always follow the manufacturer's advice on Health and Safety and guidelines for application and curing times.

Used for sheet joints, painted and galvanised surfaces in direct contact with Glass-Fused-to-Steel panels, perimeter base fillet type seals and minor internal repairs. Due to its high performance specification TS plus is also used for more specialist applications requiring chemical and temperature resistance. Sikasil Pool

Silicone sealant used in conjunction with Sikaflex TS Plus for the internal primary seal for onerous and/or high temperature applications. Sikaflex 221

Only to be used in applications where fast cure is an essential requirement. (Remedial, maintenance etc). Sikaswell S2

Hydrophilic base seal. Sikalastomer 710

Perimeter bond breaker used in conjunction with Sikaflex TS Plus for tanks above 33.2m diameter and 11.2m in height. Sika Primer 3N

Concrete primer for perimeter base seals. Sika Primer 210T

Galvanised surfaces on roof top stiffener and floor foundation angles. Sika Cleaner 205

General cleaner for Glass-Fused-to-Steel surfaces and pre-treatment for silicone sealant overpointing. Permastore Repair Kit Corroless EP

Minor repairs to panel surfaces and sheet edges. NOTE 1: Sealant and Primers may vary in accordance with the process design criteria of the structure. Doc Ref: P132 Rev 9

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PART ONE – Section 7 Applications Requiring the use of Silicone Sealants

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CONSTRUCTION

WITH

SILICONE

SEALANTS

1.

For applications where the operational temperatures exceed 50 C or the process conditions are particularly onerous silicone sealant is used.

6.

Following a minimum period of 24 hours check that the Sikflex TS Plus internal sealant is touch dry.

7.

Prior to applying the internal silicone sealant as detailed above the existing Sikaflex TS Plus sealant fillet must be cleaned with cleaner 205.

8.

Over point the internal sheet edge sealant with silicone sealant as detailed above.

9.

This method of sealant construction will also be used for Glass-Fused-to-Steel Floors.

₀

2.

The tank is constructed using Sikaflex TS Plus with the external tank sheet edges over pointed with Sikaflex TS Plus. Sheet surfaces must be clean and dry when the Sikaflex TS Plus construction sealant is being applied. See note 2 under ‘Standard Sealants and Primers Part 1 Section 6’.

3.

The Sikaflex TS Plus sealant is applied over the bolt holes as normal but controlled around the internally exposed sheet edges to minimise excess sealant being extruded into the contact area of the tank.

4.

Use the extruded Sikaflex TS Plus sealant around the internal sheet edges to form a small protective fillet.

5.

It is essential to fillet all internal sheets edges, vertical and horizontal correctly. For the inside of the tank structure the Sikaflex TS Plus is over pointed with silicone sealant. For the outside of the tank structure external pointing is completed using Sikaflex TS Plus sealant only.

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10. For foundation perimeter sealing the Sikflex TS Plus fillet should also be over pointed with silicone sealant.

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PART ONE – Section 8 Tank Fixing Details

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To be used in conjunction with the Fixings Chart on Page 26 of this Guide.

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Tank Fixing Details

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PART ONE – Section 9 Structure Dimensions

PART ONE – Section 9 Structure Dimensions

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INTERNAL DIMENSION OF STRUCTURES Nominal Radius Model Diameter Reference 11 14 17 20 22 25 28 31 34 36 39 42 45 48 50 53 56 59 62 64 67 70 73 76 78 81 84 87 90 92 95 98 101 104 106 109 112 115 118 120 123 126 129 132 134 137 140 143

Sheets Per Ring 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51

Nominal Radius

Metres

Feet and Inches

1.708 2.135 2.562 2.988 3.415 3.842 4.269 4.696 5.123 5.550 5.977 6.404 6.831 7.258 7.685 8.112 8.359 8.965 9.392 9.819 10.246 10.673 11.100 11.527 11.954 12.380 12.808 13.235 13.662 14.089 14.516 14.942 15.369 15.796 16.223 16.650 17.077 17.504 17.931 18.358 18.785 19.211 19.638 20.065 20.492 20.919 21.346 21.773

5' 7' 8' 9' 11' 12' 14' 15' 16' 18' 19' 21' 22' 23' 25' 26' 28' 29' 30' 32' 33' 35' 36' 37' 39' 40' 42' 43' 44' 46' 47' 49' 50' 51' 53' 54' 56' 57' 58' 60' 61' 63' 64' 65' 67' 68' 70' 71'

Model Diameter Reference

7¼" 4⅞"

9¾" 2½" 7¼" ⅛" 4⅞"

9¾" 2½" 7⅜" ⅛" 4⅞"

9¾" 2½" 7⅜" ⅛"

5" 9¾" 2⅝" 7⅜"

¼" 5" 9⅞" 2⅝" 7⅜"

¼" 5" 9⅞" 2⅝"

7½" ¼" 5⅛"

9⅞" 2¾" 7½" ⅜" 5⅛"

10" 2¾" 7½ ⅜" 5⅛"

10" 2¾" 7⅝" ⅞"

5¼"

146 148 151 154 157 160 162 165 168 171 174 176 179 182 185 188 190 193 196 199 202 204 207 210 213 216 219 221 224 227 230 233 236 239 242 245 248 251 254 257 260 262 265 268 271 274 277 280

Sheets Per Ring 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99

Metres 22.200 22.627 23.054 23.481 23.908 24.335 24.762 25.189 25.616 26.042 26.470 26.896 27.323 27.750 28.177 28.604 29.031 29.458 29.885 30.311 30.738 31.166 31.593 32.020 32.447 32.873 33.300 33.727 34.154 34.581 35.008 35.436 35.863 36.290 36.717 37.144 37.571 37.998 38.425 38.851 39.278 39.705 40.132 40.559 40.986 41.413 41.840 42.267

Feet and Inches 72' 74' 75' 77' 78' 79' 81' 82' 84' 85' 86' 88' 89' 91' 92' 93' 95' 96' 98' 99' 100' 102' 103' 105' 106' 107' 109' 110' 112' 113' 113' 116' 117' 119' 120' 121' 123' 124' 126' 127' 128' 130' 131' 133' 134' 135' 137' 138'

10" 2⅞" 7⅝"

½" 5¼" 10⅛" 2⅞" 7⅝"

½" 5¼" 10⅛"

3" 7¾" ½" 5⅜" 10⅛"

3" 7¾" ⅝" 5⅜"

10¼" 3" 7¾" ⅝" 5⅜"

10¼" 3" 7⅞" ⅝"

5½" 10¼" 3¼" 8" ¾" 5⅝"

10½" 3¼" 8" ⅞"

5¾ 10½" 3¼" 8" ⅞"

5¾" 10½" 3¼" 8⅛"

For tank diameters larger than those charted above please contact Permastore for further advice. Doc Ref: P132 Rev 9

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PART TWO – Section 1 Foundation Design and Sealing Options

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Permastore Construction Guide FOUNDATION OPTIONS 1.

DESIGN

AND

Foundation Design and Sealing Options SEALING

Ring Beam and Infill Design

Generally considered to be the least complex design and favoured where the installation team has responsibility for the base and tank construction. The ring beam can be installed prior to arrival of the tank kit on site and the foundation bolts positioned whilst the concrete is still wet, if required. The base slab (infill) is generally poured following construction of the starter or base ring. Alternatively it is poured following completion of the tank shell if the structure is being built using construction jacks.

Rebate Base Design Utilised mainly where the base design and construction is by a third party, it facilitates a proven concept to achieve effective hydrostatic containment where two separate contracting agents have responsibility for a common workface. 2.

Flat Base Design

Generally as (2) overleaf, but requires a very high standard of base concrete construction to achieve an acceptable level and flatness. It is essential that these levels of workmanship are attained to enable the tank to be successfully constructed and sealed. This concept has a limited range of use and is only recommended for experienced installation teams.

TANKS UP TO AND INCLUDING 8 RINGS HIGH


TANKS ABOVE 8 RINGS HIGH.

TANKS ABOVE 8 RINGS HIGH

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Foundation Design and Sealing Options BASE PERIMETER SEAL OPTIONS 1. Perimeter Fillet Seal a)

Pour concrete to the level specified on the drawing or level with existing foundations. Ensure that the concrete completely fills the gap between the ring beam or floor slab and the base angle. NOTE: It is recommended that a concrete vibrator is used to ensure that the concrete fully flows beneath and around the base angle.

LIMITED TO TANKS WITHIN THE RANGE 3.4M (11FT) – 16.2M (53FT) DIAMETER AND 1 RING - 6 RINGS HIGH

b)

When the concrete has cured sweep clean the perimeter of the foundations inside the tank to remove any surface debris.

c)

Clean the Glass-Fused-to-Steel surface immediately above the concrete level inside the tank to ensure good adhesion for the sealant fillet. See Note 2 under 'Standard Sealants and Primers' Part 1 Section 6.

d)

Apply primer to the concrete base only extending approximately 50-60mm (2 inches) inwards from the tank wall.

e)

Review the instructions for use of the perimeter sealant being used and then apply the sealant.

f)

Allow to cure as manufacturer's instruction.

4. Agricultural Slurry Tank Base Design

Identical to Ring Beam and Infill design with the exception that case-in anchor bolts are always supplied.


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2. Perimeter Fillet Seal with Bond Breaker for tanks above 33.2m diameter and 11.2m in height.

a) Pour concrete to the level specified on the drawing or level with existing foundations. Ensure that the concrete completely fills the gap between the ring beam or floor slab and the base angle. NOTE: It is recommended that a concrete vibrator is used to ensure that the concrete fully flows beneath and around the base angle.

b) When the concrete has cured sweep clean the perimeter of the foundations inside the tank to remove any surface debris. c) Clean the Glass-Fused-to-Steel surface immediately above the concrete level inside the tank to ensure good adhesion for the sealant fillet. See Note 2 under 'Standard Sealants and Primers' Part 1 Section 6. d) Apply primer to the concrete base only extending approximately 50-60mm (2 inches) inwards from the tank wall. e) Apply the perimeter bond breaker as detailed and ensure it is touch dry and then apply the perimeter seal fillet. f)

Allow to cure as manufacturer’s instructions.

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PART TWO – Section 2 Tank to Base Clamping and Levelling Systems

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Clamp and Levelling Systems NOTE: Always maintain an even adjustment of the levelling plates.

ANCHOR BOLT AND CLAMP 1.

Brush clean the top surface of the ring wall. Mark out the tank radius on the concrete surface.

2.

Place shims inside each anchor bolt at the correct radius from the centre point of the tank. Check the levels of the shims to within 1.5mm (1/16 inch).

3.

There must be a minimum gap of 25mm (1 inch) between the foundation angles and foundation concrete.

4.

It is essential that anchor clamps are clamped directly onto a shim pack.

2.

From the tank centre stake mark out the foundation angle radius on to the levelling plates. Place the foundation angles round the tank circumference, on top of the levelling plates, ensuring that when sheets are fitted, vertical seam joints are adjacent to a levelling system, with another levelling system situated mid sheet and all are equally spaced.

3.

Fit the hold down clamps onto the outer anchor bolt and foundation angle and loosely tighten, whilst checking that the correct radius is maintained.

THROUGH ANGLE FIXING (EMBEDDED AND FLAT BASE TANKS) 1.

For Through Angle fixing the base angle will be supplied pre-punched to identify the location of the anchor bolts. Position of bolt holes to be used is shown on construction drawings.

2.

For applications where the tank is constructed from the base ring upwards (stack building) the foundation bolts are installed following completion of the base ring. For applications where the tanks are constructed using jacks the foundation bolts are installed following completion of the final ring of sheets (base ring).

3.

It is essential that shim packs are located in close proximity to the foundation bolts and PVC isolation washers are fitted.

LEVELLING SYSTEM 1.

Using a Dumpy level (or similar) check that all the levelling plates are installed to within 1.5mm (1/16 inch), whilst always maintaining a minimum of 25mm (1 inch) gap between the foundation concrete and the underside of the base angles. Tighten the levelling plates.

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PART THREE

Section 1

Assembly of Tanks From the Base Ring Upwards

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Assembly Methods

ASSEMBLY OF TANKS AND SILOS FROM THE BASE RING UPWARDS

7.

SPECIAL NOTE: If the levels or the concentricity are not maintained, problems will occur when building higher rings, especially the final stiffener angles.

The Base Ring of Sheets

1.

Refer to bolt charts for correct bolt placement and assembly.

2.

Apply sealant to the inside face of the foundation angles and proceed to fit the foundation sheets ensuring that angles are fitted with an equal overlap from each vertical joint and tapered inserts are fitted at the vertical joint positions of the foundation angles. See Note 2 under 'Standard Sealants and Primers' Part 1 Section 6.

Fit all remaining base sheets.

Diameter Up to 13.7m (45ft) From 14.5m to 26.5m (48ft to 87ft) 27.5m (90ft) and above

8.

Circularity ± 6mm (¼ inch)

± 12.5mm (½ inch) ± 25mm (1 inch)

After the vertical joints are fully expanded top and bottom fit the two bolts left out for this operation and tighten to correct torque. NOTE: Check the concentricity of the structure at this point.

9.

3.

4.

Working in a clockwise direction around the circumference, apply sealant to the inside face of the vertical overlapping sheet seam ensuring all bolt holes are covered. Leaving out 2 bolts from each vertical seam (the top bolt and the bolt positioned 5 up from the bottom), install all remaining bolts checking that sealant has been applied over each bolt hole before inserting the bolts.

Tighten all bolts to 65Nm (46ft-lb) torque with the exception of bolts through tapered inserts, which should be tightened to 32Nm (23ft-lb) only.

10. Remove the temporarily fitted top stiffener angles. 11. Using a pointing trowel, fillet off the vertical seam sealant as shown below.

SPECIAL NOTE: It is essential that top angles are fitted temporarily to maintain the tank shape. Bolt the angles to the top of the ring of sheets, without sealant, using 6 bolts equally spaced and tightened to 25Nm (18ft-lb).

5.

Before tightening the bolts in the vertical seam ensure that it is fully expanded using the 2 bolt holes previously left for this operation (see Note 4 above).

6.

For tank sheets above 10mm thick, fully expand vertical joints using a tank sheet hydraulic joint expander assembly. A sheet joint expander kit is available from Permastore. 12. We recommend the installation of an expanding peripheral waterstop as shown on the project base drawing.

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Assembly Methods

INTERMEDIATE RINGS

1.


2.

Build the second ring of sheets using suitable lifting equipment.

3.

Mark all structure holes for the wind stiffener clip angles with chalk before assembling the ring of sheets. As the sheets are constructed fit the clip angles at the same time as the structure bolts are installed.

7.

Before tightening a partially completed ring, ensure the end sheets are truly vertical, as these sheets tend to lean.

8.

Apply sealant fillets to cover sheet edges on vertical and horizontal joints inside and outside the tank.

9.

Remove the temporarily fitted top stiffener angle.

FOUR CORNER JOINT VIEWED FROM EXTERIOR OF TANK SPECIAL NOTE: It is essential that top angles are fitted temporarily to maintain the tank shape. Bolt the angles to the top of the ring of sheets, without sealant, using 6 bolts equally spaced and tighten to 25Nm (18ft-lb).

4.

Fully expand concentricity.

5.

For tank sheets above 10mm thick, fully expand vertical joints using a tank sheet hydraulic joint expander assembly. A sheet joint expander kit is available from Permastore.

6.

Tighten from the centre of each sheet to either corner on the horizontal seams; tighten the vertical seam from the corner joint to the top ensuring that the seam is expanded.

vertical

joints

and

check

10. All bolt heads are to have a sealant squeeze out and the 4 corner joints should be completely covered with sealant.

NOTE: If possible, do not start a new ring of sheets late in the day if only a small number of sheets will be completed. Where it is not possible to complete a full ring of sheets by the end of the day, secure each end of the unfinished ring with ropes to prevent any possible overnight wind damage.

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PART FOUR

Section 1

Assembly of Tanks and Silos Using Construction Jacks

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Assembly Methods

ASSEMBLY OF TANKS AND SILOS USING CONSTRUCTION JACKS

k)

Jacks are generally used to construct tanks and silos which are 3 rings high and above. They are also regularly used to construct structures with roofs or starter rings. (Contact Permastore for further advice on suitability and usage).

l)

Permastore construction jacks are regularly maintained and load tested. Copies of test certificates are available to confirm suitably.

Important Information a)

Permastore construction jacks are designed to build only Permastore structures.

b)

The construction jacks must only be operated by trained and competent personnel.

c)

The jacks must not be used when wind speeds exceed 25mph (40km/hr). If the wind speed approaches this figure the structure should be lowered and anchored down to the base. Special care is needed when gusting winds can exceed this figure.

d)

e)

f)

h)

Before Commencement of Work

1.

With jacks vertical, check gearbox oil is up to level plug. (Use EP90 or equivalent).

2.

NOTE: For c) & d) above, ensure that anchors are removed prior to jacking.

Check splines on gearbox and PTO shafts for wear or damage and ensure that locking pins are free and oiled. Grease splines on both and ensure PTO shaft guards are fitted correctly.

3.

An electrically driven 'Master Jack' drives the jack units via PTO drive shafts.

Examine motor couplings and drive shaft splines for wear and check motor/gearbox alignment.

4.

Check all turnbuckle threads are free and oiled and stays are in good condition.

5.

Examine jack carriage assembly for damage or wear and oil jack drive screw.

The structure should be lowered and anchored each evening in case of overnight winds.

Standard operation is for one jack per vertical seam of the structure with one master jack. For certain applications slave gearboxes are available to reduce the requirement for standard construction jacks (see page 45). Extra jacks may be used and extra master drive jacks required for special structures. It is recommended that jacks be used on both seams adjacent to platforms and similar heavy ancillaries.

g)

CONSTRUCTION JACK MAINTENANCE

Before setting up the jacks it is essential to ensure that they stand on a firm, level foundation. The jack bases must be level to prevent overloading of individual jacks and to ensure that the structural load is evenly distributed across all of the jacks. The jacks must be positioned vertically, fixed to the concrete base using the foundation bolts provided or clamped to the bottom sheet/angle and supported by centre and side stays. Centre and side/top stays must be utilised on every installation. Special length top stays are provided for use with Slave Gearboxes.

i)

The jack spacer plate must be used between the carriage and structure sheet.

j)

Ensure that electricity supply cables cannot be accidentally damaged or cut, cover over if necessary. The use of armoured cable is recommended.

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Daily Checks

1.

Check jack lifting carriage assemblies for damage and security.

2.

Check jack retaining clamp for tightness.

3.

Examine jack support stays and pins and check jacks for being upright with masons level.

4.

Make sure that jack lifting bolts and nuts are always in good condition. Any replacement bolts must be to the correct grade and shank length. (Minimum Grade 8.8).

Weekly Checks

1.

Jack gearbox oil levels.

2.

Grease rollers on rear of jack carriage plate.

3.

Grease PTO shaft universal joints.

4.

Oil jack drive screws.

NOTE: Ensure that all jacking equipment is kept clean and in a serviceable condition during the construction period.

After construction is complete, fully examine all parts for wear and lubricate before packing away.

Page 41 of 97


Assembly Methods 3.

TYPES OF CONSTRUCTION JACK

Within our stock of construction jacks that are available for hire we have two distinctly different models. 1.

Slave Gearboxes

One advantage associated with the low-level jacks is the opportunity to utilise 'slave gearboxes' for a specified range of applications. Slave gearboxes are low cost units that allow safe construction utilising a reduced number of jack legs.

High Level Gearbox

The high-level gearbox jacks have the gearbox and transmission shafts located at the top of the jack body and have a swivel mounted base plate for conical foundations. The high level jacks are tested for a safe working load of six tonnes (13,200 lbs).

The advantage being more cost effective use of the jack legs by reducing the amount required to construct a specified vessel and facilitating increased use of a limited number of high cost assets. Special length top stays are provided for use with slave gearboxes to ensure positive location of the assembled equipment. Centre stays and top stays MUST be utilised on EVERY installation. A recommended usage chart for slave gearboxes and low-level jacks is included for reference (see page 45).

2.

Low Level Gearbox

The low-level gearbox jacks have the gearbox and transmission shafts located at the bottom of the jack body and the drive motor is an independent unit which is floor mounted between two jacks. The low-level jacks are tested for a safe working load of four tonnes 8,800 lbs).

SETTING UP FOR JACK CONSTRUCTION

1.

Set up base angle, level and check concentricity.

2.

Place jacks inside structure on base.

3.

Assemble top row of sheets onto base angle. Apply sealant to vertical seams only; locate onto base angle with four bolts per sheet. Expand sheets and tighten vertical bolts to 65Nm (46ftlb).

4.

Re-check

concentricity and clamp down base

angles. 5.

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Place jacks at every vertical seam as standard layout ensuring that they are the correct distance from the tank wall. For Low Level Jacks the dimension from inside tank wall to the front face of the Jack Column should be 140mm and for High Level Jacks 56mm.

Page 42 of 97

Permastore Construction Guide 6.

7.

8.

Assembly Methods

Use level to check jack base plates. Pack up with shims if necessary as the jacks must be on level base datum to prevent stress during lifting and possible gearbox damage due to over-run. Level carriage plates and bolt to sheet using spacer plates. Make sure that carriage plates are at their lowest position without fouling the jack stops. Fit support struts, check that jacks are vertical and clamp down with foundation bolts through the base plates or use clamps.

OPERATION OF JACKS

1.

Jack bolts must be of the correct size and strength.

2.

Ensure that the jacks are in the low position before connecting to the sheets and a spacer is located between the carriage and the sheet.

3.

In all cases a jack bolt must be fitted to every accessible hole in the carriage plate. A minimum of three jack bolts must always be utilised.

4.

Loosely tighten the jack bolts and raise the structure until weight is being taken on the jacks. Ensure that the jack bolts are located in the bottom of the carriage plate slots and tighten to 65Nm (46ft-lb) torque.

5.

Raise the top ring of sheets to the correct height for installation of the next row of sheets or roof.

Install the motor mounting assembly to the master jack and connect the drive shaft and cover guard.

CAUTION: Isolate drive motor and remove drive shaft before commencement of work.

WARNING: When raising the jacks they must not be run up to the end stops. The carriage plate must not travel beyond the safe working area. This will result in damage to the unit and if persistently abused this could result in failure of the equipment.

6.

Apply sealant and hang the second row of sheets in an anti-clockwise direction. Leave out the bolts at the position the jacks will locate on the next lift.

7.

Complete a full ring of sheets and fully expand the vertical seams before tightening.

8.

Fit wind stiffener assemblies where applicable as full rings are completed.

9.

Loosely pull in any gaps in sheet faces, tighten from centre to both corners on the horizontal seam and tighten the vertical seam from the corner down to the bottom ensuring that the joint is fully expanded.

CARRIAGE PLATE ASSEMBLY

9.

Fit PTO shaft guards over the universal joint connections.

10. Check oil levels and lubricate screw thread.

10. When the ring of sheets is complete lower the structure onto supports until the weight is taken off the jacks. Remove the jack bolts and spacer bars and lower the jacks to locate on the next sheet. Check that the carriage plates jam whilst lowering. WARNING: When lowering the jacks they must not be run up to the end stops. The carriage plate must not travel beyond the safe working area. This will result in damage to the unit and if persistently abused this could result in failure of the equipment INSTALLED HIGH LEVEL JACK ASSEMBLY Doc Ref: P132 Rev

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11. Repeat the procedure until the structure is complete. Page 43 of 97


Assembly Methods

JACK SYSTEM USAGE CHART (For guidance only) Series 1400 Low Level System Each jack leg has a safe working load (SWL) of 4000 kg (8,800 lbs). For small diameter standard tanks use a jack leg on every vertical seam. For other standard structures up to and including 5 rings high use a combination of jack legs and slave gearboxes as recommended within the usage chart. Slave gearboxes are suitable only for structure diameters included within the chart. For tank diameters outside the scope of this chart including tanks with roofs and any tank in excess of 6 rings high you must refer to Permastore for advice and confirmation of jack usage. Sheets Per Ring (SPR)

Model Diameter (ft)

Jack Legs o (N of units)

Slave Gearbox o (N of units)

6

17

6

0

7

20

7

0

8

22

8

0

9

25

9

0

10

28

10

0

11

31

11

0

12

34

9

3

13

36

9

4

14

39

10

4

15

42

10

5

16

45

10

6

17

48

10

7

18

50

10

8

19

53

10

9

20

56

11

9

21

59

11

10

22

62

12

10

23

64

12

11

24

67

13

11

25

70

13

12

26

73

14

12

27

76

14

13

28

78

15

13

29

81

15

14

30

84

16

14

31

87

16

15

32

90

17

15

33

92

17

16

34

95

18

16

35

98

18

17

36

101

19

17

37

104

19

18

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Assembly Methods

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Sheets Per Ring (SPR)

Model Diameter (ft)

Jack Legs o (N of units)

Slave Gearbox o (N of units)

38

106

20

18

39

109

20

19

40

112

21

19

41

115

21

20

42

118

22

20

43

120

22

21

44

123

23

21

45

126

23

22

46

129

24

22

47

132

24

23

48

134

25

23

49

137

25

24

50

140

26

24

51

143

26

25

52

146

27

25

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PART FOUR

Section 2

Assembly of Tanks and Silos Using Construction Jacks and a Starter Ring

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Assembly Methods

SETTING UP FOR TANK/SILO CONSTRUCTION USING JACKS AND A STARTER RING

6.

Continue installation Part Four - Section 1.

as

described

in

Standard base structures may incorporate a starter ring located onto the base angle. Starter rings are generally used where a tank/silo may be extended at some future date. They are also used to progress installation of the base foundation and can be supplied in advance of the main tank kit. Starter Ring 1.

Locate jack support plate (Part No. 512805) at starter ring vertical seam. Space out with washers to allow for thickness of base sheet.

2.

Set up construction jacks as standard procedure.

3.

Secure jacks by drilling and rawl bolting through jack base plate into concrete or use clamps.

4.

Fit structure support brackets (Part No. 523355) to starter ring.

5.

Hang top row of sheets onto jack carriage plates using sealant, fit all bolts, expand seams top and bottom, check circularity and tighten to torque 65Nm (46ft-lb).

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PART FOUR

Section 3


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Assembly Methods

ASSEMBLY OF DOUBLE SKIN TANK SHEETS 1.

A Permastore Site Supervisor is recommended for the installation of double skin sheets, unless the Distributor has prior supervised experience.

2.

Refer

3.


4.

Ensure double skin sheet assembly rig is provided and ready prior to construction.

5.

Lift the inner double skin sheet onto the assembly rig ensuring the sheet is positioned as shown below.

6.

Apply sealant to the vertical and horizontal bolt seams and to the outer surface of the inner sheet.

7.

Lift the double skin outer sheet onto the inner sheet ensuring the holes are aligned as shown in the view below. Bolt the inner and outer sheet together using the 8-off bolt holes in the centre of the sheet.

8.

Lift the assembled sheets into position for the tank shell construction and apply sealant to the vertical and horizontal bolt seams of the outer double skin sheet.

to Construction Guide PART THREE Section 1 for general tank construction guidance.

Outer double skin tank sheet

Inner double skin tank sheet

Assembly rig

VIEW OF ASSEMBLED INNER AND OUTER DOUBLE SKIN SHEETS ON ASSEMBLY RIG

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Assembly Methods

9.

Fully expand vertical joints using the double skin tank sheet hydraulic joint expander assembly. A sheet joint expander kit is available from Permastore.

10.

The vertical joint and corner assembly arrangements for double skin and quad row vertical series 1400 sheet joint interchanges are shown below as viewed from the exterior of the structure.

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PART FIVE

Section 1

Annular Tank Construction

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Annular Tank Construction

ANNULAR TANKS

Annular tank systems are generally used for continuous process applications. They provide a costeffective solution where floor space is at a premium. The basic concept is two circular tanks of equal height, one inside the other. 1.

When constructing an annular tank system, first mark out on the foundation both the inner and outer tank internal diameters. Also mark a line from the centre which crosses the internal and external marked diameters for each of the baffle walls. NOTE:

Before commencing construction work check all the relevant drawings for layout configurations of tanks, especially if they incorporate launders, baffle walls or revolving bridges. It is important to ensure the correct orientation and fitment of all constituent parts. 2.

Construct the inner tank in accordance with the instructions specified in Part Three or Part Four of this guide. Ensure the baffle wall fixing holes are in line with the marked positions. Fi t external stiffener angles as specified on the arrangement drawing and all exposed fixings on the exterior of the inner tank must be protected using the plastic nut caps provided.

3.

Construct the outer tank around the inner tank taking care to ensure that the baffle wall fixing positions are in alignment and the datum levels are consistent with the inner tank.

PLAN VIEW OF TYPICAL ANNULAR SYSTEM

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PART FIVE

Section 2

Backfilled Tank Construction

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the intersection. Where it is essential that heavy traffic passes close to the tank or parks close to the tank for process purposes, the tank should be backfilled locally with concrete.

BACKFILLED TANKS

Backfilled tanks are designed to be constructed either wholly or partially below ground level. IMPORTANT NOTICE: All work must be undertaken by competent building crews familiar with the relevant regulations with particular regard to Health and Safety. Furthermore, it is the responsibility of the building crew undertaking these works to consider each particular installation, its environment and the specific risks therein prior to commencement of work, to determine the protective equipment required by personnel and to plan the safe system of work that should be adopted in order for the task to be carried out safely. 1.

Check all relevant drawings for layout configurations. It is important to ensure the correct orientation and fitment of all constituent parts.

2.

The tank should be constructed in accordance with the instructions specified in Part Three or Part Four of this guide.

3.

During construction it is essential that all the stif fener bands are positioned as shown on the general arrangement drawing and all exposed fixings on the exterior of the tank must be protected using the plastic nut caps provided.

4.

Before the backfill material is laid the tank must be successfully hydrostatically tested to ensure complete expansion and as a check on all joints. The water level must be maintained during backfilling to prevent possible load damage.

5.

The backfill should be placed in layers 300mm (12 inches) deep. Each layer must be fully circumferential. Take care if excavated earth is being re-used to backfill the tank, this may contain larger stones or boulders which may damage the tank. Sand or pea gravel are the preferred backfill materials but if you are using local earth then hardboard sheets should be used to prevent damage.

6.

If the backfill material is to be compacted the density of the compacted material should not be greater than the surrounding conditions. Ensure that machinery used for compaction does not damage the tank walls.

7.

Unless the tank is specifically designed to such loads all heavy vehicles or equipment should not be allowed close to the tank wall. An angle drawn at 45° from the tank wall/base level gives

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8.

Where tanks are designed to be backfilled with a fully drained material a positive drainage system should be provided.

RECEPTION PITS Important Notice

All work must be undertaken by competent building crews familiar with the relevant regulations with particular regard to Health and Safety. Furthermore, it is the responsibility of the building crew undertaking these works to consider each particular installation, its environment and the specific risks therein prior to commencement of work, to determine the protective equipment required by personnel and to plan the safe system of work that should be adopted in order for the task to be carried out safely. 1.

Reception pits are available in a range of sizes up to a maximum 20ft diameter, usually 1½ rings deep. They are mainly utilised in agricultural applications as gravity fed collection tanks.

2.

For excavation dimensions refer to the approved reception pit drawings (supplied separately).

EXCAVATE THE PIT AREA 1.

Mark out the perimeter.

2.

Determine the total depth and diameter of the pit excavation required and proceed with the excavation, allowing an additional 600mm (24 inches) on the diameter. Should there be any risk of soil collapse the excavation area may have to be increased accordingly. DANGER: Under no circumstances should anyone get into the excavation at this stage.

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ASSEMBLE THE PIT 1.

The pit should be assembled, above ground, on a suitable level and firm foundation, ie on an area of concrete adjacent to the excavated site.

2.

Apply sealant to one vertical and one horizontal seam only, ensuring the bolt holes are covered.

3.

Start by bolting just the top full ring of sheets together using the standard overlap right over left.

4.

Fit the top stiffener angles to the ring of sheets using tapered inserts at sheet overlap points.

5.

Fit anchor rods at regular spacing as shown on the approved pit drawing.

13. Check levels and shim until the pit is level to + or 1.5mm (1 / 16 inch) with the shims provided and the top of the pit is to the required finished height (allowance for pit top or grid to be included). 14. Place the reinforcing mesh in the base area, ensuring correct concrete cover by supporting the mesh with chairs/stools and then pour the concrete into the pit centre. Ensure that the concrete flows out underneath the foundation angles by using a concrete vibrator. Ensure that levels inside and outside the pit are correct by referring to the approved pit drawing. 15. Compacted granular fill may be used in the pit excavation to within 100mm (4 inches) of the foundation angles, unless the distance between the edge of the reception pit and the main tank is less than 2.5m (8ft 3in), when it is then advisable to backfill with concrete that half of the pit excavation which is nearest to the main tank. Determine the amount of compacted granular fill required, taking into account that all inlet pipes and anchor rods around the top of the pit are to be encased in mass concrete. Refer to approved pit drawings.

Temporarily fit the foundation angles to the pit without sealant. Use 4 equally spaced bolts per angle and tighten to 32Nm (23ft-lb). 6.

Tighten all sheet bolts to 65Nm (46ft-lb).

7.

The assembled top ring can now be lifted using suitable lifting equipment fixed at four equally spaced points around the pit top. While the pit is suspended, remove the foundation angles and fit the lower ring of sheets. Fit the foundation angles with sealant, using tapered inserts at the sheet overlap points.

8.

Tighten all bolts to the correct torque.

9.

Fillet all sheet edges both inside the pit and outside.

10. The assembled pit can now be lowered into the excavation and should be suspended clear of the base whilst a crew member goes inside. 11. From inside the pit the crew member should place concrete blocks in position under the foundation angle ensuring they are on a level and firm footing. 12. Check that the pipe opening is set to the centre line of the main tank and lower the pit onto the concrete blocks. Doc Ref: P132 Rev 9

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16. When the concrete has cured sufficiently, after a minimum of 3 days, apply a surface primer to the concrete base only, as shown, wait for it to become tack free, then seal inside the pit with a fillet of sealant between the concrete and GlassFused-to-Steel sheet.

WARNING: Serious damage will result to the Glass-Fused-to-Steel if a flame torch is used to dry out base concrete to install the sealant seal.

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PART SIX

Section 1

Roof Construction

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Roof Construction

INTRODUCTION IMPORTANT NOTICE: All work must be undertaken by competent building crew familiar with the relevant regulations with particular regard to Health and Safety. Furthermore, it is the responsibility of the building crew undertaking these works to consider each particular installation, its environment and the specific risks therein prior to commencement of work. To determine the protective equipment required by personnel and to plan the safe system of work that should be adopted in order for the task to be carried out safely. As a general rule all roofs should be constructed at ground level. Dependent upon the type of roof being installed, site and environmental conditions and other project-specific factors, roofs can be constructed at varying stages of the installation process. In some extreme cases alternative methods of roof construction may affect the roof design. It is therefore extremely important to evaluate this subject at the earliest opportunity and plan accordingly. The construction methods described within this section may not apply to all installations. For advice on alternative methods of construction please contact Permastore.

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PART SIX

Section 2


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Roof Construction

TROUGH DECK ROOF CONSTRUCTION IMPORTANT NOTICE: All work must be undertaken by competent building crew familiar with the relevant regulations with particular regard to Health and Safety. Furthermore, it is the responsibility of the building crew undertaking these works to consider each particular installation, its environment and the specific risks therein prior to commencement of work. To determine the protective equipment required by personnel and to plan the safe system of work that should be adopted in order for the task to be carried out safely.

7.

Position centre row of cladding across tank. Pilot drill and fix with the self-tapping screws provided.

8.

Fit rest of cladding working from centre row outwards. Refer to drawing for special panel layouts and overlaps. If access is required onto any area of the roof that has already been clad then spreader/crawler boards must be utilised and safety rails fitted along any exposed edges. Alternatively safety netting can be suspended underneath the roof.

NOTE: Roofs up to and including 8.53m (28ft) diameter are constructed at low level before the tank is jacked to full height. Roofs above 8.53m (28ft) diameter are generally built following completion of the tank.

9.

Trim off around edge of top stiffener angle using a suitable portable nibbler or hand saw.

1.

Study drawing for layout of support brackets, beam configuration, upright supports etc.

2.

Pre-assemble beams if required.

3.

Fix support brackets to top angle at positions indicated on drawing.

4.

Fit primary beams and uprights (where required) ensuring correct location to provide a shallow fall across the roof.

5.

Fit secondary beams and tie rods if required.

6.

Anchor vertical supports to base.

10. Seal between top stiffener angle and cladding with aerosol canned foam (where required). 11. Fit perimeter flashing around the tank using the self -tapping screws provided. 12. Check all coated parts for damage and repair if necessary.

TROUGH DECK ROOF SHOWING BEAM END AND GRP FLASHING

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PART SIX

Section 3


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Roof Construction

20° STAINLESS STEEL ROOF CONSTRUCTION IMPORTANT NOTICE: All work must be undertaken by competent building crew familiar with the relevant regulations with particular regard to Health and Safety. Furthermore, it is the responsibility of the building crew undertaking these works to consider each particular installation, its environment and the specific risks therein prior to commencement of work. To determine the protective equipment required by personnel and to plan the safe system of work that should be adopted in order for the task to be carried out safely. 1.

20° Roofs are constructed at ground level.

2.

Assemble top ring of sheets as detailed with Part Four Section 1.

3.

Set roof cap centre support at the height specific on the adjacent sketch, dependent on the roof

5.

Where special height sheets form part of the supply these will be specified on the project drawings.

6.

Fit the centre roof cap onto the roof cap centre support column.

7.

For roof diameters 6.83m (22ft) and above the panels are manufactured in two pieces and panels should be pre-assembled prior to construction.

8.

The first panel fitted must overlap the sheet vertical joint by at least one clear hole pitch.

9.

Successive roof panels must be constructed in a clockwise direction ensuring fitment of the internal radial stiffener angles as each new panel is installed.

diameter.

10. Do not tighten the panels to the roof cap until the whole assembly is complete. 4.

Variations to tank height can also be calculated using the combination of sheet heights identified.

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Roof Construction

SPECIAL NOTES 1.

Fit tapered inserts on top of roof panel overlap points before fixing to underside of roof cap. Also at the roof panel to tank overlap points and where the tank shell vertical joints overlap.

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PART SIX

Section 4


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Roof Construction

EXTERNAL TAPERED BEAM GLASS-FUSEDTO-STEEL ROOF CONSTRUCTION IMPORTANT NOTICE: All work must be undertaken by competent building crew familiar with the relevant regulations with particular regard to Health and Safety. Furthermore, it is the responsibility of the building crew undertaking these works to consider each particular installation, its environment and the specific risks therein prior to commencement of work. To determine the protective equipment required by personnel and to plan the safe system of work that should be adopted in order for the task to be carried out safely. 1.

Tapered Beam roofs are constructed at ground level.

2.

Assemble top ring of sheets including the top angle, as detailed in Part Four Section 1.

3.

4.

Set up suitable load bearing scaffold in the center of the tank at the correct height to support the roof during building. Refer to assembly drawings for positions of inserts, sealer plates, bolt lengths etc. Roof top stiffener angle galvanised parts to be primed with Sika Primer 210T along joint face and allowed to dry before applying sealant.

6.

When assembling Glass-Fused-to-Steel roof panels the bolt torque setting should be 65Nm (46ft-lb) generally and 32Nm (23ft-lb) where tapered inserts are fitted.

7.

Check that centre support ring is level and set to the correct height above the top stiffener angles.

8.

Check roof layout for access upstand/flange positions and walkways and proceed to install the first four roof beams, placing them at 90° intervals.

9.

Assemble the next four beams in the centre of the four beams already installed. Proceed to assemble the rest of the beams using the same technique.

10. When all beams are in position the roof panels can be installed. 11. Proceed to fit outer roof panels in an anticlockwise direction by slackening and supporting the beams and inserting the panels between the beam and the top angle, ensure that the rubber inserts are correctly placed. It is advisable to assemble at least three panels before tightening and always leave two loose panels between the one being installed and the one being tightened. 12. Following completion of the outer ring of panels commence installation of the inner roof panels, again in a clockwise direction. 13. Apply sealant to upper surface of roof panel, along all bolt seams except at the top (shortest) edge. With suitable lifting equipment proceed to lift roof panels into position and fix to under side of beams installing all bolts in opposite sides of adjacent beams and lower edge seam. 14. Complete the full ring of panels torque up bolts in panel previously installed and apply sealant fillet along the edges of this panel. 15. Proceed to assemble the roof using these techniques on subsequent rings.

EXTERNAL BEAM ROOF 5.

To assist when hanging very large panels a hole is punched for attachment of a special lifting bracket. After fitting the panel apply sealant around the hole, insert a store bolt and tighten to 65Nm (46ft-lb).

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16. Apply sealant and fit roof cap plates together with roof cap stiffener. 17. The centre annulus support scaffold must not be removed until all roof panels are fitted.

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PART SIX

Section 5


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Roof Construction

EXTERNAL PARALLEL BEAM GLASSFUSED-TO-STEEL ROOF CONSTRUCTION IMPORTANT NOTICE: All work must be undertaken by competent building crew familiar with the relevant regulations with particular regard to Health and Safety. Furthermore, it is the responsibility of the building crew undertaking these works to consider each particular installation, its environment and the specific risks therein prior to commencement of work. To determine the protective equipment required by personnel and to plan the safe system of work that should be adopted in order for the task to be carried out safely. 1. 2.

Paralled Beam roofs are constructed at ground level. Assemble top ring of tank sheets including the top angle as detailed within Part Four - Section 1.

3.

Set up suitable load bearing scaffold in the center of the tank at the correct height to support the roof during building.

4.

Refer to assembly drawings for positions of inserts, sealer plates, bolt lengths etc. Roof top stiffener angle galvanised parts to be primed with Sika Primer 210T along joint face and allowed to dry before applying sealant.

5.

To assist when hanging very large panels a hole is punched for attachment of a lifting bracket. After fitting the panel apply sealant around the hole, insert a store bolt and tighten to 65Nm (46ft-lb).

6.

When assembling Glass-Fused-to-Steel roof panels the bolt torque setting should be 65Nm (46ft-lb) generally and 32Nm (23ft-lb) where tapered inserts are fitted.

7.

Check that centre support ring is level and set to the correct height above the top stiffener angle.

8.

Check roof layout for start datum and install starter roof panels. Ensure that rubber inserts are correctly positioned.

9.

Install first four roof beams, placing them at 90° intervals. Refer to sketches on the following page for details of beam end attachment.

10. Install next four beams central to the four beams already installed. Proceed to install the rest of the beams following the same procedure until all beams are in position. 11. Following completion of the outer ring of panels commence installation of the inner roof panels, again in a clockwise direction. 12. Apply sealant to upper surface of roof panel, ie along the bolt seams except at the top (shortest) edge. With suitable lifting equipment proceed to lift roof panel into position and fix to underside of beams installing all bolts in opposite sides of adjacent beams and lower edges seam. 13. Complete the full ring of panels working in a clockwise direction, torque up bolts in panel previously installed and apply a sealant fillet along the edges of this panel. 14. Proceed to assemble the roof using these techniques on subsequent rings. 15. Apply sealant and fit roof cap plates together with roof cap stiffener. 16. The centre annulus support scaffold must not be removed until all roof panels are fitted.

PARALLEL

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Roof Construction

PARALLEL BEAM END ATTACHMENT DETAILS

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PART SIX

Section 6

Glass Reinforced Plastic (GRP) Roof Construction

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Roof Construction

GRP ROOF CONSTRUCTION IMPORTANT NOTICE: All work must be undertaken by competent building crew familiar with the relevant regulations with particular regard to Health and Safety. Furthermore, it is the responsibility of the building crew undertaking these works to consider each particular installation, its environment and the specific risks therein prior to commencement of work. To determine the protective equipment required by personnel and to plan the safe system of work that should be adopted in order for the task to be carried out safely. 1.

GRP roofs are constructed at ground level.

2.

The design and shape of GRP roofs vary considerably and for this reason the following instructions are very generalised.

3.

Set up suitable load bearing scaffold in the centre of the tank at the correct height to support the roof during building.

4.

Using a mobile crane, place first roof panel positioning the panel onto roof support angles and centre support scaffold.

5.

Join remaining roof panels together installing sealer strip or sealant in between joints and bolt together using the stainless steel setscrews, washers and nuts provided. Tighten in accordance with the manufacturers instructions.

6.

After

7.

Place roof cap into position, drill through roof cap and roof panels with a suitable size drill to accommodate the fixings provided. Remove roof cap, clean drill swarf apply sealant, install fixings provided and tighten in accordance with the manufacturers instructions.

8.

Do not remove centre roof support scaffold until all bolts are in position and tightened around the perimeter of roof and roof cap is corr ectly installed.

installing all the roof panels drill out holes in outer roof support flange to align with holes already in outer roof support angles. Lift up roof sheets from roof support angles using a pinch bar or similar, clean out drill swarf, apply sealant in between roof support angles and roof flange. Install store bolts provided and tighten to 30Nm (20ft-lb).

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PART SIX

Section 7


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Roof Construction

PRESSURE TESTING OF ROOFS IMPORTANT NOTICE: All work must be undertaken by competent building crew familiar with the relevant regulations with particular regard to Health and Safety. Furthermore, it is the responsibility of the building crew undertaking these works to consider each particular installation, its environment and the specific risks therein prior to commencement of work. To determine the protective equipment required by personnel and to plan the safe system of work that should be adopted in order for the task to be carried out safely. 1.

2.

Where the project specification dictates a pressurised roof these are designed to withstand internal pressures and vacuums. Following construction and hydrostatic testing it is important to test the roof to ensure that it is effectively sealed and meets the specified test/specification conditions.

Equipment needed:-

6.

Use a water and detergent mixture to test all roof seams and flange connections.

7.

Pressure must be maintained during the period of test, generally one hour maximum.

8.

Mark any leaks that need to be repaired.

9.

Release pressure from structure and repair any leaks. If leaks were repaired, re-pressurise and check they are sealed. NOTE: It is advised that tests are carried out on a calm and cloudy day. Variations in temperature due to sun, rain or wind can greatly affect internal pressure. These changes will cause pressures to fluctuate and will need to be compensated for during the test. Extreme fluctuations may cause a serious over/under pressurisation of roof resulting in damage if venting is not adequate.

pressure

10. Ensure the roof is vented before draining internal water to prevent implosion.

b)

Electric extension cables to reach the top of the structure.

11. When pressure testing to specific test/contractual conditions it is advisable to ensure the customer's representative witnesses the test.

c)

Manometer ('U' tube water gauge).

d)

Pipe connection kit.

e)

Appropriate personal safety equipment.

f)

Knapsack sprayer.

a)

Electric blower required.

capable

of

3.

Seal all tank outlet pipe flanges and access hatches.

4.

Fill tank with water to operational level.

5.

Install blower connection kit and pressurise roof to test pressure.

CAUTION: WHEN FILLING AND/OR DRAINING A TANK IN PREPARATION FOR OR FOLLOWING ROOF PRESSURE TESTING IT IS IMPORTANT TO ENSURE THAT ROOF INSPECTION HATCHES, VENTS, APERTURES ETC ARE LEFT OPEN TO PREVENT AN OVER-PRESSURE OR VACUUM SITUATION OCCURING WHICH MAY RESULT IN PERMANENT DAMAGE TO THE TANK STRUCTURE.

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PART SEVEN

Section 1

Construction of Glass-Fused-to-Steel Floors

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Glass-Fused-to-Steel Floor Construction

GLASS-FUSED-TO-STEEL FLOOR CONSTRUCTION 1.

Prior to proceeding with the installation ensure you have read and understood the layout drawings for the type and size of floor to be assembled.

2.

From the centre point of the prepared foundation mark a circle equivalent to the nominal tank diameter plus 150mm (6 inches).

3.

Mark out the 0°-180° and the 90°-270° centre lines ensuring they are clearly identifiable outside of the circle.

4.

Lay base angles to confirm location of shim packs and install shim packs to the CORRECT radius and level.

5.

Install the bitumen sand (asphalt/tank base) within the tank circle as detailed on the layout drawing and level with the shim packs.

6.

Care must be taken to ensure the asphalt surface is level. A slight rise to the centre is desirable.

7.

Lay polythene sheet and cover asphalt before installing floor.

8.

Special care must be taken to protect the floor panels during construction of the floor and tank.

9.

10.

11.

Before each sheet is laid, insert the bolts in readiness for fitting the adjoining sheets, secure the bolts with the 'push on' fixing (Part Number 208059091).

Apply sealant ensuring a liberal covering around the protruding bolts. For Glass-Fused-to-Steel floors up to and including 21.347m (70ft) diameter the perimeter holes for fixing the floor to the foundation angles are pre-drilled.

12.

For Glass-Fused-to-Steel floors above 22.2m (73ft) diameter and above the perimeter holes need to be drilled on site.

13.

Lay the first panels (row 'D') and ensure that the first row of floor sheets is in a straight line before tightening; very important on large tanks.

FLOOR LAYOUT 14.

Lay subsequent panels in sequential order as specified on construction drawing.

15.

Fit tapered inserts at the sheet overlap areas between the floor sheets and the base angles.

16.

Fit full rows of sheets before tightening bolts using the standard torque settings to assist with alignment.

17.

Fillet all sheet edges.

18.

As there is no expansion pressure on a flat surface it is not necessary to use a joint expander during construction.

19.

For floors up to and including 21.347m (70ft) diameter that are pre-drilled lay the perimeter panels first and work inward.

This is feasible due to the circular accuracy of smaller diameter tanks.

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Glass-Fused-to-Steel Floor Construction

20.

Providing the procedures have been carefully followed there should not be any cause for leakage, however, it is advisable for the crew leader to carefully inspect all areas of the sealing joints and fillets. This may be your last chance to ensure a seal.

21.

Dependent on the method of construction for the tank cylinder, protective nut caps should be fitted now if not using jacks. Where jacks are being used to construct the tank the nut caps should not be fitted until after the tank is constructed and all jack equipment removed.

22.

Floor fixings should be treated with Sika Primer 210T and coated with sealant prior to fitting nut caps.

23.

Install the foundation angles and where they join fit the joint sealer angles (Part Number 559299) as shown. Floor foundation angles joint faces to be primed with Sika Primer 210T and allowed to dry before applying sealant. Construct the first

FLOOR PLATE

BASE ANGLE CONNECTION

26.

Continue building the tank structure referring to the relevant section of this guide.

27.

When the structure is complete drill and fit the foundation bolts and PVC isolation washers and install the internal perimeter sealant fillet.

ring of tank cylinder sheets in the conventional manner. 24.

Tapered inserts should also be fitted at the vertical sheet joints.

SECTION THROUGH FOUNDATION BOLT

25.

Expand the vertical sheet joints before tightening the bolts to 65Nm (46ft-lb).

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28.

Fillet the outside of the structure with concrete if specified/required.

29.

Fit plastic nut caps to the floor area if not already installed.

30.

The finished floor assembly MUST be wet swab tested at this stage (Part Ten Section 2) and any repair work undertaken. For details of suitable repair procedures refer to Part Twelve Section 1 of this guide.

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PART EIGHT

Section 1

Cone Tank Construction

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Cone Construction

CONE TANK CONSTRUCTION

SKIRT MOUNTED STRUCTURES

IMPORTANT NOTICE: All work must be undertaken by competent building crews familiar with the relevant regulations with particular regard to Health and Safety. Furthermore it is the responsibility of the building crew undertaking these works to consider each particular installation, its environment and the specific risks therein prior to commencement of work, to determine the protective equipment required by personnel and to plan the safe system of work that should be adopted in order for the task to be carried out safely. Introduction 1.

Cones and structures are designed to conform with the product being stored and customer requirements. The connection and design techniques will remain similar.

2.

Except for skirt mounted structures a crane will be required to lift the structure and cone onto the supporting steelwork.

3.

Construction layout and techniques are the same as standard tank design, ie joint overlap and bolt torque.

4.

A tapered insert is used at angle and sheet transition overlap areas.

5.

Cone structures are designed to be supported by Glass-Fused-to-Steel sheets (skirt mounted) or sectional steel (steel-frame mounted). The actual design being determined during the enquiry stage when the operational and storage details are clear.

6.

Skirt mounted cone structures can, in most cases, be assembled using the conventional installation equipment traditionally used to construct Permastore tank and silos.

7.

Steel frame mounted cone structures generally require specialist lifting equipment to ensure a quality and safe construction.

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1.

Build tank structure as standard procedures ensuring that for the final lift before the hip- joint the jacks are taken down to their lowest position. This will ensure the extra height required to install the hip-joint. Lift jacks to their highest position and check that clearance is sufficient to assemble hip- joint and first row of skirt sheets.

2.

Check all relevant drawings and assemble hip joint leaving out section at jack positions and ensure that correct length bolts are used, do not fit those where stiffener ring is to be connected. Leave bolt finger tight.

3.

Hang first row of sheets leaving out any bolts where stiffener ring is to be fitted.

4.

Lower structure onto support and disconnect jack bolts.

5.

Lower jacks and connect for next lift, raise structure sufficiently to allow completion of hip joint and fitting first row of cone sheets. After tightening cone sheets assemble and fit external stiffener. Raise structure again to hang second row of skirt sheets.

6.

Continue to build structure adding cone sheet rings and internal stiffener brackets as required. Fit internal stiffener on completion of skirt sheets.

7.

Fit cone outlet adapter to final row of cone sheets before they are tightened.

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8.

Cone Construction

Typical view showing the layout and assembly of cone structure.

STEEL FRAME MOUNTED CONE STRUCTURES

1.

These structures are supported below the cone hip-joints directly onto a steel superstructure and will require a crane on site, time will be dependent on method of build.

2.

In most cases the top row of cone sheets would be assembled on a firm, level area of ground. Attach the cone support ring and cylinder base angle.

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3.

Check that the ring of sheets are level, exp and the vertical seams and tighten. Do not tighten the bolts from the cone support ring to base angle at this stage.

4.

Lift cone ring with crane using either internal bracing or a spreader frame to prevent distortion of the ring. Further rows of cone sheets can be added at this stage depending on the size of crane employed.

5.

Lift the cone onto the platform and bolt down. Tighten all bolts in base angle and channel.

6.

Choose a firm level piece of ground and build the main structure using construction jacks. Ensure that the jacks are securely anchored down. Fit a suitable lifting bracket to each vertical seam on the top row of sheets.

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7.

Cone Construction

Using a spreader bar lift structure onto top of cone and couple up. Ensure that a good sealant fillet is applied inside to fully cover the hip- joint area.

ALTERNATIVE METHODS OF CONE CONSTRUCTION 1.

The structure can be built by using the crane instead of construction jacks. Build the top row of sheets and roof on a suitable level piece of ground. Fit lifting brackets and install other rings of sheets while suspended.

2.

Lift pre-assembled structure and couple to cone at ground level before installing onto steel platform.

3.

After fitting the cone onto the platform, scaffold can be placed internally and externally around the top of the cone and steelwork and the main structure built directly on top of the cone using construction jacks. This system will require load bearing scaffolding and special brackets manufactured to support the jacks.

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PART NINE

Section 1

Construction of Ancillary Products

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Ancillary Products

GENERAL GUIDANCE NOTES

The ancillary products contained within this part of the Construction Guide have all been designed by Permastore or have been technically assessed for suitability with our standard product. Although Permastore offer a comprehensive range of ancillary products there are situations where customers manufacture their own ancillary products or where unique process requirements dictate the use of special equipment, fixtures and fittings. It is extremely important to ensure the technical suitability of any ancillary equipment that is not supplied by Permastore and is to be mounted or fixed to one of our structures. The un-necessary introduction of dis-similar metals for example can induce an electrolytic cell within the as constructed tank. Permastore cannot accept any responsibility for problems associated with the attachment/fitment of ancillary equipment by others unless those products have been approved for use, in writing, by our Engineering Department. IF IN DOUBT, ASK.

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Ancillary Products

PROTECTIVE NUT COVERS

FLANGE CONNECTORS 1.

Flange connectors are available in a range of options, the standard supply is detailed below:-

They can also be purchased separately for aesthetic purposes if required.

2.

Refer to the assembly drawings for the correct orientation/position.

2.

Check the relevant drawings for the position of the protective nut covers (eg backfilled tanks have nut caps fitted in the area of backfill only, unless otherwise specified).

3.

3.

Once the nut has been tightened to the final torque, ensure that there is plenty of sealant squeeze-out around the nut and washer, then push the protective nut cover onto the nut and washer. Use either a rubber or wooden mallet to install tight caps.

When installing flange connectors, apply sealant around the sheet aperture where the connector is in contact with the Glass-Fused-to-Steel plate. Position the connector and backing flange and fit the fixing bolts. Tighten fixings to 50Nm (36ftlb).

4.

Fillet the internal edges of the connector assembly ensuring that the bore is not restricted by sealant.

1.

4.

Plastic nut covers are supplied as standard with Glass-Fused-to-Steel floors, backfilled tanks and inner annular tanks. They are provided to protect the exposed fixings only where there is a risk of contents or environmental corrosion.

If the sealant around the nut and washer has cured, scrape off the cured sealant and apply a bead of sealant to the inside of the protective nut cove and push onto the nut and washer assembly.

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Ancillary Products

VENTS AND ROOF HATCHES

TANK WALL ACCESS MANWAYS

1.

Pre-assemble vent or hatch if required.

1.

2.

Apply sealant around roof aperture where the vent or hatch is in contact with the Glass-Fusedto-Steel sheet. Fit and tighten fixing bolts to 50Nm (36ft-lb).

Tank wall access manways are supplied as a complete assembly including a pre-cut aperture

sheet and are designed to complement the particular application required. The standard manway is 800mm diameter with a hinged cover to facilitate safe and easy access.

3.

Glass reinforced plastic or aluminium fittings should only be tightened to 30Nm (20ft-lb).

4.

Steel fitments should be tightened to 50Nm (36ft-lbs).

5.

2.

Dependent upon the specification supplied it may be necessary to use a mobile lifting rig to position the manway frame.

3.

Apply sealant around the sheet aperture inside and outside the tank, ensuring sufficient coverage to effectively seal the flange plates.

4.

Position the backing plate inside the tank and insert a small quantity of fixings.

5.

Position the external frame and fit nuts and washers to the locating fixings.

6.

Insert the remaining fixings and tighten to the standard torque setting.

7.

Fillet the internal and external edges of the frame assembly ensuring effective edge protection.

8.

Position and fix the access door ensuring ease of operation and effective closure.

Fillet all internal and external edges with sealant.

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Ancillary Products

LADDERS AND PLATFORMS 1.

Ladders and platforms are supplied in various configurations according to the height, diameter, market standards and client specification. It is therefore very important to refer to the assembly drawing prior to construction to ensure the correct layout details.

2.

Pre-assemble the ladder platform sections and mark the position on the tank of the ladder and platform support brackets.

3.

Ensure the tank bolts have been omitted during tank construction.

4.

Apply sealant to the tank wall and support brackets before installing the fixings.

5.

The ladder sections and platform assembly can then be fitted to the support brackets at low level as the tank is being built.

6.

Base ladders should be fitted to confirm suitability but removed before leaving site and handed to the client for safe storage. Base ladders should only be accommodate controlled access.

fitted

to

7.

Install the platform base onto the relevant support brackets and then complete the assembly by fitting the upright support and handrails.

8.

Several variations of the standard ladder and platform options are shown for reference only on the following pages.

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SECTIONAL VIEW OF INNER AND OUTER LADDER ASSEMBLY.

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Ancillary Products

INDUSTRIAL LADDER AND PLATFORM OPTIONS

OPEN TOP TANK LADDER ASSEMBLY

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OPEN TOP TANK LADDER ASSEMBLY WITH OPTIONAL 1M SQUARE VIEWING PLATFROM

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OPEN TOP TANK LADDER ASSEMBLY WITH OPTIONAL 2M x 1M VIEWING PLATFORM

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Ancillary Products

AGRICULTURAL LADDER AND PLATFORM OPTIONS OPEN TOPPED AGRICULTURAL TANK LADDER ASSEMBLY WITH OPTIONAL 2M x 1M (6ft x 3ft) PLATFORM WITH CENTRE FLOOR HATCH

5 RING TANK


4 RING TANK

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3 RING TANK

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Ancillary Products

CIRCUMFERENTIAL LAUNDERS 1.

Launders are used to remove clarified or settled s ettled liquids from the top of process tanks.

2.

Within our standard range of ancillaries there are two distinctive systems available.

10. Fit weir plates in position at the correct level ensuring the sealer strip is effectively placed to avoid seepage.

'U' TYPE LAUNDER SYSTEM 'Z' TYPE LAUNDER SYSTEM 3. 4.

5.

'Z' type launders are mounted directly onto the tank wall with a separate scumboard assembly. Ref er er to all relevant drawings before commencement of work to ensure correct assembly layout. Launder systems should be fitted at ground level.

Position first launder section at correct height and central to the outlet flange. Some launders may incorporate a special dropped dropped outlet. Locate this section first.

11. 'U' type launders are mounted on brackets with an internal scum board. 12. Refer to all relevant drawings before commencement of work to ensure the correct assembly layout. Launder systems should be fitted at ground level. 13. Install mounting brackets as detailed around the perimeter of the tank. 14. Position the first launder section central to the outlet flange. Some launders may incorporate a special drop box. Locate this section section first.

6.

Where a GRP 'Z' type launder is being installed drill holes 14mm (½ inch) diameter through the launder trough section using the holes in the Permastore sheet as a template.

15. Proceed to mount launder trough on the support brackets around the tank in an anti-clockwise direction, ensuring that each section is bolted together with sealant and fixings supplied.

7.

Apply sealant to mating face of launder trough and Permastore sheet, fit launder in place and bolt in position.

16. Fix launder trough to mounting brackets using pre-punched pre-punched holes, ensuring good sealant application around fixings.

8.

Proceed to fit launder trough around tank in an anti-clockwise anti-clockwise direction ensuring that each section is bolted together with sealant and fixings.

17. Fit weir plates in position at the correct level ensuring the sealer strip is effectively positioned to avoid seepage.

9.

The last section of launder trough may need trimming (GRP only) on the plain section end to ensure correct joint with outlet section.


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Ancillary Products

BAFFLES AND BAFFLE WALLS 1.

Internal baffle assemblies are utilised to provide a homogenous mixture of contents in process tanks.

2.

Directly dependent on the height of the tank the baffle assembly may be designed as a single price structure or a modular concept.

3.

Refer to all relevant drawings before commencement of work to ensure correct assembly layout. Baffle assemblies and baffle walls should be installed at ground level.

4.

Apply sealant to the contact surfaces and fit vertical support angle frames to the tank wall.

5.

Fit Glass-Fused-to-Steel baffle plates to the angle frame.

2.

Apply sealant to contact faces and fit vertical support angles to inner and outer tank.

3.

Fit baffle wall to support angles.

4.

Fit top angle to baffle wall using splice plates to join to inner tank.

5.

After fitting floor angles drill out concrete and fit expanding anchor bolts.

6.

After completion of baffle walls install concrete haunch over floor angles if specified.

7.

Apply sealant to contact faces and fit weir weld assembly to inner tank.

8.

Fit splice plates to weir weld assembly to join to top stiffener angles.

BAFFLE WALL 1.

Baffle walls are utilised to separate different sections or processes within a tank.

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Ancillary Products

AGRICULTURAL VALVE KIT (SLUICEGATE)

ANODE

CATHODIC

PROTECTION SYSTEM

1.

Refer to approved valve assembly drawings.

2.

When installing the valves and trunking or pipework, ensure any PVC joints are glued correctly.

3.

Support the pipe or trunking and valves in the trench, to allow a minimum of 150mm (6 inches) concrete cover over the pipework.

4.

Valves must be installed with flow direction arrow facing the reception pit to ensure that the valve plate is under flow pressure against the seal.

5.

Wrap the entire length of PVC pipework in polythene sheeting.

6.

Care should be taken when pouring the concrete to ensure the pipework or trunking is not disturbed or damaged.

7.

Concrete clearance must be maintained at the top of the valve to allow for top plate removal.

8.

Fitting the outlet into the reception pit may require the cutting of the Glass-Fused-to-Steel sheet (Refer to Part Eleven Section 1).

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1.

There are some applications where the process requirements or commercial factors dictate that routine inspection and maintenance is impractical. Where such conditions exist Permastore recommends that a suitable cathodic protection system is installed, monitored and maintained. Cathodic protection systems can provide a low cost, long term solution to protect your investment.

2.

For further information please refer to Document Ref: P145 'Guidance Notes for the Application and Use of Sacrificial Anode Cathodic Protection Systems'.

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PART TEN

Section 1

Checklist Following Construction

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Checklist

a)

Ensure sufficient sealant has been applied correctly.

Base ladders removed and stored safely by the client.

b)

Access doors fitted/closed correctly

a)

c)

Pressure test blanking plates removed.

d)

No debris/fixings left in the tank that could damage process equipment.

e)

Any other obvious or client specified activities.

CHECKLIST AFTER CONSTRUCTION 1.

b) 2.

To provide full cover to all areas of sheet overlap; To provide a squeeze out of sealant around bolt heads, nuts and washers.

Have bolts been fitted to all holes used for joint expansion or jack location?

3.

Have all sheet edges been pointed correctly to give full protection both internally and externally?

4.

Have all ancillaries attached to Glass-Fused-toSteel coated sheets been fully coated with sealant on contact surfaces before being bolted?

5.

Have tapered inserts been used in appropriate areas at top and bottom angles?

6.

Are the levels and concentricity in accordance with recommendations?

7.

Are all the bolts within the specified torque limits?

8.

Has the peripheral base seal been applied correctly and checked for adhesion?

9.

Are all ancillary items securely fastened?

13. Ensure all packing and waste materials have

been cleared up, disposed of properly and the site is left tidy. All COSHH substances and contact packaging must be disposed of in a safe manner commensurate with the manufacturers data sheet. 14. Inspect

the structure with the customer's representative and assuming everything is in order request his authorisation of a Construction Completion Certificate.

10. Has the full structure been examined carefully

and swab tested internally to identify any installation damage and have the damaged areas been repaired? The application of this test must be witnessed by the customers site representative following which the 'On Site Wet Swab Testing Results Chart' (Doc Ref: 02.04.02 Appendix 7) and the 'Certificate of Completion' (Doc Ref: 02.04.02 Appendix 4) must be authorised by the sub-contractor and the customers representative. For full instructions on repair procedures refer to the Permastore Inspection and Maintenance Manual Document Reference P110. 11. Check serial plate has been fitted. 12. Check that the Safety Awareness signs provided

within the tank construction kit are installed as instructed (refer to Item 6, of 'Forward' Section of this guide) 13. Ensure the structure has been left in a safe and

secure condition for following operations/testing. For example:

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PART TEN

Section 2

Low Voltage Continuity Testing on Site

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Testing on Site

LOW VOLTAGE CONTINUITY (WET SWAB) TESTING ON SITE

All structures should be wet swab tested on the internal surface following construction. We recommend that for tall structures being built with jacks, that a check on the continuity of the internal Glass-Fused-to-Steel coating is conducted on a ring by ring basis during construction. This will identify any minor repairs that may be necessary following construction and will reassure the end user that the product has a defect free containment surface. It is important to advise the customer's site representative prior to testing, giving sufficient time for the test to be witnessed and approved following completion. The internal surface of the structure should be clean and free of surface contaminants. Testing is carried our using an Elcometer Model 269 Wet Swab Unit set at 9 volts. The test sponge shall be wet but not saturated with water containing a small amount of detergent to reduce surface tension. In the unlikely event that a discontinuity is found the following repair procedure should be adopted. The identified area will be inspected for any signs of corrosion. Should corrosion be evident the area must be treated locally with Corroguard, abraded and then allowed to dry for a minimum of 6 hours and then overcoated with a 2mm ( inch) thick layer of sealant overlapping the discontinuity area by 20mm (¾ inch) all round. The area of repair will again be subjected to low volt test proving satisfactory repair.

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PART ELEVEN

Section 1

Troubleshooting

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Troubleshooting inside of the structure) and cover the bolt head area of the sheet liberally with sealant.

TROUBLESHOOTING Introduction

This section has been compiled to assist the construction team to resolve minor assembly issues and undertake replacement or modification work. One of the features of a Glass-Fused-to-Steel bolted construction tank is the ability to modify the structure on site to accommodate new or changed process conditions. It is also possible to extend some structures in height using either a top or bottom extension but in all cases reference should be made to Permastore to ensure suitability of proposed change.

2.

c)

Re-insert

d)

Should the leak be serious, ie more than a dribble, it may be necessary to part the sheets with a small hard wooden wedge and insert sealant to the complete overlap area with a pallet knife.

the bolts and tighten to the prescribed torque. Replace the internal sealant fillet and repoint.

Corner Joint Leaks a)

Remove existing sealant around the corner joint extending beyond the nearest bolt in all four directions.

b)

Remove the corner bolt completely and slacken the four bolts immediately surrounding the corner bolt.

c)

Wedge open the joint internally with a hard wooden wedge and inject sealant into the open joint.

d)

Repeat point (c) externally.

e)

Replace the corner bolt, nut and washer.

LEAKAGE REPAIRS

f)

WARNING: If the structure has been in use there may be potential hazards from toxic gases or substances.

Tighten the corner and four surrounding bolts to the specified torque.

g)

Re-point

IMPORTANT NOTICE: All work must be undertaken by competent building crew familiar with the relevant regulations with particular regard to Health and Safety. Furthermore, it is the responsibility of the building crew undertaking these works to consider each particular installation, its environment and the specific risks therein prior to commencement of work. To determine the protective equipment required by personnel and to plan the safe system of work that should be adopted in order for the task to be carried out safely.

Please refer to the Health and Safety information included within the Foreword of this guide. In the unlikely event that leaks are in evidence on the structure it may only be possible to effect a reseal from the inside. The structure must then be drained completely and the affected area thoroughly dried before commencement of repair. NOTE: Should the leak appear on the outside at a bolt, the source of the leak is not necessarily at the bolt head but may start through the sheet overlap.

Should the leak appear on the outside at a sheet overlap the source of the leak is not necessarily at the same point of the sheet overlap but may start from the bolt head. 1.

3.

Perimeter Seal Leaks

If the leak is from the base area, again remember that the point of the leak showing externally is not necessarily the source and may start from any point of the perimeter seal up to 3m ( 10ft) from the leak. The source may also be from an area of the floor because of porous concrete. For perimeter seal leaks:a)

Check the adhesion to the tank wall and concrete foundation.

b)

Suspect areas should be cut away 500mm (18 inches) either side of the affected area and the concrete cleaned and dried.

c)

Apply concrete primer as specified for each type of perimeter seal.

d)

Apply new sealant to the area cut away.

Bolt or Seam Leaks a)

b)

To repair, mark the point of the leak precisely on the outside of the tank before draining the tank. After draining the tank remove completely all structure bolts and internal sealant fillet within 150mm (6 inches) of the leak. Insert fresh sealant into the bolt holes (from the

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the corner joint and surrounding seams with new sealant.

NOTE: For all sealant repairs allow a minimum of 10 days to cure before refilling the tank. For temperatures below 15°C an extended cure period will be required.

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Permastore Construction Guide REMOVAL OF FLAT SPOTS ON CORNER JOINTS OF A STRUCTURE

Troubleshooting THE

DRILLING AND CUTTING HOLES IN GLASSFUSED-TO-STEEL SHEETS

1.

Remove all bolts surrounding the four corner joints, clean, apply new sealant in the joints and loosely install new bolts.

WARNING: Do not use disc grinders or flamecutting equipment to cut holes in Glass-Fused-to-Steel sheets. Always use electric drill and jig-saw.

2.

Secure a wooden support inside the tank with a M10 ( inch) diameter eye bolt through bolt hole in sheer joint and pull out flat spot to the correct shape of the tank. This is best done using a chain block or similar anchored to a suitable pulling point. After pulling out flat spots tighten bolts to the correct torque. Remove chain block, replace eye bolt and apply sealant fillets to blend in with the existing fillets.

Always use eye protection when cutting or drilling

REMOVING AND REPLACING A GLASSFUSED-TO-STEEL SHEET

Mark the position of the hole to be drilled and dot punch the centre. Start with a small pilot drill and gradually increase the drill size to the required size to the required hole diameter.

WARNING: If the structure has been in use there may be potential hazards from toxic gases or substances.

Please refer to the Health and Safety information included within the Foreword of this guide. 1.

If the structure has been in use there may be potential hazards from toxic gases or substances. refer to the Health and Safety information included within the Foreword of this guide. Please

DRILLING HOLES

CUTTING OPENINGS

1.

Apply masking tape over the areas of the openings to be cut. Mark out the opening and dot punch the inside edge. Drill out to 10mm (13 / 32 inch) and using a jig-saw cut around the marking opening. Recommend Bosch blades type T118B.

2.

After cutting or drilling remove all traces of swarf and burred edges.

3.

Ensure that all edges have been covered with sealant on completion of work.

Set up scaffold to a working height on the outside and inside of tank adjacent to where sheet is to be removed. To remove the sheet, carefully take out all the sheet fixing bolts from the sheet overlaps. It may be necessary to remove the bolts on adjoining sheets at the four sheet overlap joint for the distance of about 300mm (12 inches). Using wooden wedges gently prise the sheet joints apart. Using suitable lifting equipment remove tank sheet. Thoroughly clean sealant from the sheet overlap joints.

2.

sheets.

To fit replacement tank sheet, sealant must be applied to all the overlap faces and with wooden wedges prise a gap between the adjoining sheets as with removal. When the replacement sheet is lowered into position with suitable lifting equipment, ensure sealant is applied between the prised open joints and applied to the replacement bolts before fitting.

PERMASTORE REPAIR INSTRUCTIONS FOR USE

KIT

1.

Corroless EP is a two part glass reinforced rust stabilising primer.

2.

Surface Preparation

Steel should be clean and free from any loose Glass-Fused-to-Steel coating, oil, grease or rust. Abrade the surface and surrounding 25mm (1 inch) of sound Glass-Fused-to-Steel with medium grit emery cloth.

When all bolts are fitted tighten to the standard torque and apply sealant fillets over sheet edges to blend in with the existing fillets.

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Permastore Construction Guide 3.

Troubleshooting 5.

Mixing and Application

Mix the two components at a 1:1 ratio and apply without delay using a small, clean brush. Ensure that the material overlaps onto the abraded Glass-Fused-to-Steel. Do not over brush.

Precautions normally taken when handling chemicals should be observed. The material must not come into contact with foodstuffs or food utensils. The use of protective clothing, goggles, barrier cream and rubber gloves are required. Adequate ventilation of the work area is recommended. Leaflets are available on the handling of these materials and we strongly advise they are read prior to using the products.

Externally applied repairs should be over painted the next day with locally sourced enamel paint to match the Glass-Fused-to-Steel. Internal repairs should be covered the following day with the build sealant. Ensure the sealant completely covers the repair material and extends a minimum 20mm (¾ inch) beyond the repair site. 4.

Properties

Mix ratio Working life Drying time

Touch Hard Over coating Min Max Application temp Min Max

Handling Precautions

6.

Data Sheets

Material Safety and data sheets for all sealants, primers and cleaners used to build Permastore structures are generally provided with the project documentation but are also available on request.

1:1 (by volume) 45 mins (at 18°C) 6 hours 16 hours 16 hours 3 days 2°C 30°C

Whilst every care has been taken to ensure accuracy throughout this guide Permastore shall have no liability for any loss or damage, (direct or indirect or consequential) arising out of or in connection with this guide. This guide is subject to supplementation or change at any time without notice at Permastore's sole discretion. © Copyright 2009 Permastore Limited

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APPENDIX A

5

1

6

2

3

7

4

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Page A1

APPENDIX A

9

12

10

13

11

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Page A2

APPENDIX A

14

17

15

18

16

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Page A3

Permastore Construction Guide

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