Engineering and Seismic
Our expertise covers the full spectrum of compliance at various jurisdictional levels: EPA -Environmental Protection Agency —Water run-off protection, contamination remediation, heavy metal removal and chemical treatment CWA – Clean Water Act —including the Underground Storage Tank (UST) Program and the Oil Pollution Act (OPA) under the Clean Water Act NPDES – National Pollutant Elimination Discharge System RCRAFDA – Resource Conservation and Recovery Act by Food & Drug Administration —including food containers, food processing equipment and water-vending applications NSF – National Sanitation Foundation —NSF International has been testing and certifying chemicals and products used to treat and distribute water since the inception of its Plumbing Products and Wastewater Treatment programs in 1965. Today, the vast majority of drinking water treatment chemicals and system components are tested and certified by NSF to demonstrate that they do not contribute harmful levels of contaminants to drinking water NSF/ANSI Standard 61—This provision is the nationally recognized benchmark for setting the health effect standards for all devices, components and materials that come in contact with drinking water OSHA – Occupational Safety & Health Agency —Tank accessibility, ladders, guardrails and platforms for ensuring worker safety
LOCAL GOVERNMENT UBC – Uniform Building Code —Specific Local Building Department Permit requirements UPC – Uniform Plumbing Code —Tank & Piping accessory requirements UMC – Uniform Mechanical Code —Tank design requirements UFC – Uniform Fire Code —Fire protection equipment specifications, Local fire official requirements
County Health & Environment Departments—Tank coating and maintenance issues, hazardous material storage
INDUSTRY STANDARDS AWWA – American Water Works Association —Bolted (D-103) and Welded Tank (D-100) construction and design standards, Seismic design methodology, Coating standards (D-102), Chlorination methods (C-652) NFPA – National Fire Protection Association —NFPA 22: Standard for Water Tanks for Private Fire Protection, NFPA 25: Standard for the Inspection, Testing and Maintenance of Water-Based Fire Protection Systems API – American Petroleum Institute —12B Bolted Tank Standards, 650: Large Welded tank standards and Appendices, API Specification 12F for Shop Welded Tanks. UL – Underwriters Laboratories —UL 142 for above ground single and double wall tanks, UL 58 for below ground water tank design SSPC – The Society for Protective Coatings —Standards for sandblasting and coatings tolerances and methods ASME – American Society of Mechanical Engineers —Pressure Vessel Design guidelines AWS – American Welding Society —Welding Procedures and Structural Welding Code FM – Factory Mutual —Insurance Company Fire Protection Equipment Standards
QUALITY CONTROL STEEL
Water Tank Assembly Manual ENGLISH VERSION
CONTENTS Introduction Snow, Wind and Seismic Loads Concrete OR Gravel Foundations Typical Foundation Shapes Water Tank Flat Foundation Plan Water Tank Corrugated Wall Sheets Wall Sheet Gauges Tank Assembly Procedure Tools and Equipment Required Small Tank Erection Procedures (Small tanks coming soon) Roof Assembly for Flat Seam Roofs (Flat Seam Roofs coming soon) High Rib Roof Assembly Rib Clamp, Eave Seal & Liner Installation Liner Hanger Clip Installation Roof Rib & Center Connections Weatherskirt & Cap Installation Roof Cap Installation Roof Safety Ring Installation Roof Cap Assembly Complete Roof Cap Assembly Roof Support Ring Installation Roof Support Ring Details Bolt Schedule Anchor Clip to Bottom Wall Sheet Vertical Seam Offset for Wall Sheets Access Panel Installation Exterior Ladder Installation Inlets, Outlets & Overflow Pipes Liner Penetration Designs Installation of Penetration Liner Boots in Concrete Floor (Option coming soon) Installation of Penetration Liner Boots in Corrugated Tank Side Wall Installation of Penetration Flanges in Corrugated Tanks Tank Venting Liner Information Liner Inspection Tank Sediment Liner Quality and upkeep Water Level Management Natures Elements / Wind, Ice, Snow
3 3 4 4 5 6 7 8 9 11 12 13 14 15 16 20 21 22 23 25 26 27 28 29 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
Introduction Congratulations on purchasing a QUALITY CONTROL STEEL Water Steel tank! The QUALITY CONTROL STEEL Water Steel tank is a combination of corrugated galvanized steel wall sheets, a galvanized steel roof, a flexible member liner for water containment, and a concrete or gravel foundation. Proper design of a complete water storage system can only be insured by a local engineer skilled in the water supply field. Every tank purchaser should retain a local professional engineer to design the foundation, inlets, outlets, overflow pipes and water level controls. QUALITY CONTROL STEEL can supply this service upon special request. The success of a QUALITY CONTROL STEEL water tank depends on proper assembly and erection of the tank. The following instructions will be helpful to those individuals involved in the water tank installation.
Snow, Wind and Seismic Loads The roof and sidewalls of QUALITY CONTROL STEEL Water Steel tanks shall be designed to resist snow, wind and seismic loads as required by the 2006 International Building Code, and the local Regulatory Agency issuing building permits for new construction. Minimum roof design live (snow) load is 16 psf, applied to the horizontal projection. Where required by climatic conditions or the local Regulatory Agency, roof design loads shall be arranged to satisfy local requirements. QUALITY CONTROL STEEL Water Steel tanks are designed to resist wind pressures described in the 2006 International Building Code, Wind Exposure C. QUALITY CONTROL STEEL Water Steel tanks are designed for Seismic Design Category D per the 2006 International Building Code, and AWWA D103-97, Section 12. Upon an engineer’s design requirements, the tank will be designed to resist additional seismic loads or those required by the local Regulatory Agency.
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Page 3
Concrete or Gravel Foundations The concrete or gravel foundation provides structural support for the water tank and its contents by transferring the imposed loads to the surrounding soil and underlying strata. In addition, the foundation can accommodate provisions for adequate drainage and sludge removal. Foundation design must be performed by a local engineer familiar with site conditions.
A concrete or gravel foundation is required for an approved QUALITY CONTROL STEEL tank. Foundation design is the responsibility of a local engineer retained by tank purchaser. QUALITY CONTROL STEEL can also provide this service upon special request.
Typical Foundation Shapes
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Water Steel tank Flat Foundation Plan
TANK DIA.
QTY. OF ANCHOR BOLTS
15’ 18’ 21’ 24’
10 12 14 16
A
4’-8 5/8” 4’-8 3/4” 4’-8 3/4” 4’-8 3/4”
B
15’-3 3/8” 18’-3 3/16” 21’-3” 24’-2 13/16”
C
7’-7 5/8” 9’-1 5/8” 10’-7 1/2” 12’-1 3/8”
27’
QTY. OF ANCHOR BOLTS 18
30’ 33’ 36’ 39’ 42’ 48’ 60’
20 22 24 26 28 32 40
TANK DIA.
A
B
C
4’-8 11/16”
27’-2 5/8”
13’-7 5/16”
4’-8 11/16” 4’-8 11/16” 4’-8 5/8” 4’-8 5/8” 4’-8 5/8” 4’-8 9/16” 4’-8 1/2”
30’-2 7/16” 33’-2 1/4” 36’-2” 39’-1 13/16” 42’-1 5/8” 48’- 1/4” 60’-1/2”
15’-1 1/4” 16’-7 1/8” 18’-1” 19’-6 15/16” 21’-13/16” 24’-1/8” 30’-1/4”
Gravel foundations can be used for all water tanks provided by QUALITY CONTROL STEEL. A Gravel foundation recommendation must be supplied upon special request from a QUALITY CONTROL STEEL specialist when using a gravel foundation.
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Corrugated Wall Sheets
WALL SHEET GAUGE AND COLOR CODE COLOR CODE PAINTED ON BOTTOM EDGE OF SHEET
GAUGE 20 18 17 15 14
COLOR GREEN UNPAINTED BEIGE GALVANIZED GALVANIZED
GAUGE 13 12 11 10 8
COLOR GREEN UNPAINTED BEIGE GALVENIZED GALVANIZED
Tank Wall Specifications 1. All wall sheets to 17 Ga. conform to ASTM A-446, C, Fy = 45,000 P.S.I G-115 galvanized or better. All wall sheets 15 Ga. or thicker conform to ASTM A653 SQ, Grade 57. 2. Sheets standard corrugation 2 2/3” x 1/2”. Sheets have 42 2/3” x 112 1/2” typical coverage. 3. All bolts are grade 8.2. Bolts shall meet or exceed Leland JS500 specifications. Vertical seams are bolted at 1 1/3” on center. Horizontal seams are bolted at 9 3/8” on center.
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Wall Sheet Gauges MODEL NO.
WALL SHEET GAUGES
601 20 602 20-20 603 20-20-20 604 20-20-20-20 605 20-20-20-20-20 606 20-20-20-20-20-20 801 20 802 20-20 803 20-20-20 804 20-20-20-20 805 20-20-20-20-20 806 20-20-20-20-20-20 901 20 902 20-20 903 20-20-20 904 20-20-20-20 905 20-20-20-20-20 906 20-20-20-20-20-20 1201 20 1202 20-20 1203 20-20-18 1204 20-20-18-18 1205 1206
MODEL NO.
1501 1502 1503 1504 1505 1506 1801 1802 1803 1804 1805 1806 2101 2102 2103 2104 2105 2106 2401 2402 2403 2404 2405 2406
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WALL SHEET GAUGES
20 20-20 20-20-18 20-20-18-17
20 20-20 20-20-18 20-20-18-17
20 20-18 20-18-17 20-18-17-15
20 20-18 20-18-17 20-18-17-14
MODEL NO.
2701 2702 2703 2704 2705 2706 3001 3002 3003 3004 3005 3006 3301 3302 3303 3304 3305 3306 3601 3602 3603 3604 3605 3606
WALL SHEET GAUGES
20 20-18 20-18-15 20-18-15-14
20 20-18 20-18-15 20-18-15-13
18 18-17 18-17-15 18-17-15-13
18 18-17 18-17-14 18-17-14-12
MODEL NO.
3901 3902 3903 3904 3905 3906 4201 4202 4203 4204 4205 4206 4801 4802 4803 4804 4805 4806 6001 6002 6003 6004 6005 6006
WALL SHEET GAUGES
ALL SMALL DIAMETER DIAMETER MODELS AVAILABLE SOON ALL LARGE DIAMETER MODELS SPECIFICATIONS AVAILABLE UPON REQUEST
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QUALITY CONTROL STEEL TANK ASSEMBLY METHODS QUALITY CONTROL STEEL tanks can be assembled by two people who have basic mechanical skills. The structures consist of preformed and punched galvanized steel wall sheets that are bolted together at a project site. The assembly method selected will depend on the tank size, equipment availability, project site and the people available to perform the assembly. A separate instruction book is provided with each tank that will supply much greater detail about all of the elements of tank assembly and erection. This page is only used for guidance as to which method to use for the tank assembly. GROUND UP METHOD Stand up the first two wall sheets of the bottom ring onto the foundation and bolt the vertical seams of these two adjacent wall sheets together. Two people can then lift the second ring wall sheets and bolt the bottom horizontal seam of the second ring wall sheets to the top of the first ring wall sheets already assembled. If higher rings are required, a scaffold can be used to lift and place the wall sheets. Two rope and pulley blocks can be suspended from the scaffold to lift each wall sheet up into position to allow for bolting to the ring below. Scaffolding can be added until the rings are complete. Place a scaffold in the center of the tank and construct a wood frame to support the roof angle. Place roof panels using ladders and scaffolds. ROOF LIFT METHOD (for tanks up to 2404 size) Stand up the first two wall sheets of the top ring onto the foundation and bolt the vertical seams of these two adjacent wall sheets together. Install roof clips, liner hanger clips and roof sealing gasket onto the top edge of the top ring. Place a scaffold in the center of the tank and construct a wood frame to support the roof segment angle ring. Place roof panels using ladders and scaffolds. Use a crane or roof jack to pick up the assembled roof and top ring above the foundation. Bolt the wall sheets for the second ring to the bottom of the top ring wall sheets. Lift the roof again and repeat this process, adding rings until the tank is assembled. TANK JACK METHOD (for tanks 27’ and larger) Stand up the first two top ring sheets onto the foundation and bolt the vertical seams of these two adjacent wall sheets together. Install roof clips, liner hanger clips and roof sealing gasket onto the top edge of the top ring. Place a scaffold in the center of the tank and construct a wood frame to support the roof segment angle ring. Place roof panels using ladders and scaffolds. Place hydraulic or electric tank jacks around the inside of the top ring and bolt the jacks to the ring. Use the tank jacks to pick up the assembled roof and top ring above the foundation. Bolt the wall staves for the second ring to the bottom of the top ring staves. Lift the roof again and repeat this process, adding rings until the tank is assembled.
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Tools and Equipment Required to Assemble and Erect QUALITY CONTROL STEEL TANKS There is some variation in the tool requirements for different tank sizes. Tool requirements also depend on the method used to assemble the tank. Other tools may be required for some applications. Unloading and Opening Tank Kits Razor blade knife to open boxes and cut wrapping Claw hammer and pry bar for opening skids and pallets Forklift, crane or loading dock to move skids off of trucks Layout for Tank Location Crayon or pencil and compass to lay out the tank diameter onto the concrete foundation A long board can be used to make a field compass. Drill holes in the board for the center pin and the crayon. Tape measure Tank Structure Assembly Hard hat, safety shoes, safety glasses and ear protection 5/8” tapered spud wrench for aligning bolt holes in steel sheets Air compressor and hose. (Each impact will require 4 cubic feet of air per minute @ 90 PSI. It is recommended to work with a 6 CFM air compressor.) Pneumatic impact wrench with 3/8” square drive and OIL Impact sockets with 3/8” square drive for ½” and 9/16 hex head bolts Electrical power or generator ½” step-bit or uni-bit for drilling out non-aligned holes Hack saw Flat blade screwdriver Allen bolt set Duct tape Impact drill 5/16” impact socket Rags Caulking gun Jig saw and jig saw blades 20-24 tooth metal cutting Hole saws, 3-1/4” for 2” penetration, 5-3/4” for 4” penetration ½” electric or battery drill for hole saw and hole saw mandrel Drill bit set up to ½” Step ladder Exterior ladder, interior ladder Carpenter apron Electrical extension cords Tank Anchoring to Foundation Hammer drill Masonry drill bits 3/8”,1/2”, 5/8”
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Tank Structure Erection Roof spider of steel or wood to suspend rolled roof segment ring for initial roof panel assembly Roof jack to lift small tanks Hydraulic tank jacks and power unit to lift large tanks Mobile crane to lift small tanks Two way radios or mobile phones
Outer Penetration Flange Installation Small layout compass for marking hole in tank wall for penetration flange ½” step-bit or uni-bit for drilling holes for wall penetration attachment bolts Allen bolt set Duct tape Rags Caulking gun Jig saw and jig saw blades 20-24 tooth metal cutting Hole saws, 3-1/4” for 2” penetration, 5-3/4” for 4” penetration ½” electric or battery drill for hole saw and hole saw mandrel Drill bit set up to ½” Inner Penetration Flange Installation Small and sharp retractable razor blade knife to make bolt and center holes in liner Rags and floor cushions to protect liner Bucket with smooth bottom for moving tools inside of liner Caulking gun to apply the flange sealant Duct tape to cover the holes in the flanges Paper towels to wipe up the flange sealant Ratchet wrench 3/8” drive, ¾” hex head socket for tightening penetration flange bolts Preliner and Main Liner Installation Ladder end cushions Interior ladder Sharp retractable razor blade knife 5/16” rod coupler nuts and 5/16” eye bolts to hang liner lifting pulleys from tank roof 3/8” lifting rope and 3/8” lifting ratchet pulleys to lift main liner (space lifting pulleys at 6’ to 8’ around the inside of the tank circumference) Roof cap assembly ¼” drive socket set with 5/16” socket Adjustable end wrench- small
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Page 10
Small Tank Erection Procedures
following pages
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Page 11
Roof Assembly for Flat Seam Roofs 6’, 8’ & 9’ Water Steel tanks
NOTES: 1. 2. 3. 4. 5.
Roof segment sheets fit outside wall sheet ring. Top sheets must overlap lower sheets. Use bead sealant on all seams of roof assembly for weatherproofing. Insert 5/16” x 3/4” H.H.C.S. from outside and secure with hex nut inside. For proper fitting roof, leave roof bolted loosely until roof collar ring has been installed, then tighten all roof and collar ring bolts.
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Page 12
High Rib Roof Assembly
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Page 13
Rib Clip & Eave Seal & Liner Hanger Installation
NOTES: 1. 2. 3. 4.
Place liner hanger clips over top edge of top ring of wall sheets. Install eave seal around top edge of wall sheets and over liner hanger clips. Glue rib clip sealing block to rib clip (1 per clip). (Optional). Bolt center clips and rib clips to wall sheets and roof panels as shown using 5/16” x ¾” hexhead bolts. 5. Fill all unused holes w/ 5/16” x ¾” hexhead bolts. 6. Caulk around high-rib extension of rib clip under high rib of roof panel. When installed properly, the steel tank will have a weather tight seal.
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Page 14
Liner Hanger Clip Installation CAUTION: LINER HANGER CLIPS MUST BE INSTALLED BEFORE ROOF PANELS. LINER HANGER CLIP DETAIL
/,.,.,
,,/'
-----
...,
ROOF PANEL
INSTALL LINER HANGER BRACKET OVERTANN KWALL
-
- ---------------t ---'...
I LINER HANGER BRACKET
'- ,
MAIN FLEXIBLE WATER CONTAINMENT LINER
ENLARGED DETAIL TANK SIDEWALL
GEO-TEXTILE WALL PRE LINER
LINER HANGER CLIP DETAIL
ROOFPANEL
MAIN FLEXIBLE MEMBRANE CONTAINMENT LINER
ENLARGED DETAIL TANK SII:EWAU.
GEO-TEXTlLE WALL PRE LINER NUMBER OF LINER HANGER BRACKETS REQUIRED PER TANK TANK DIAMETER
6
8
9 12 15 18 21
TANK HEIOHT NUMBER OF IN RINGS BRACKETS
3 3 3 3
3 3 3
12 18 18 24 36 48 48
TANK HEIGHTIN RINGS
NUMBER OF BRACKETS
6 6
6 6 6 6 6
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12 24 24 24 48 48 72
TANK TANK HEIGHT NUMBER OF TANK HEIGHT NUMBER OF DIAMETER IN RINGS BRACKETS IN RINGS BRACKETS
24 27 30 33 36 39 42
3 3 3 3
3 3 3
72 72
72 72 96
10e. 10S
6 6
6 6 6 6 6
TANK DIA METER
72
48
84 96 96 144 144 144
60
72 82 85 90 1re
TANK HEIGHT NUMBER OF TANK HEIGHT NUMBER OF I N RINGS BRACKETS BRACKETS
3 3 3 3
3 3
3
144 144 180 180 180 216 216
6 6
6 6 6 6 6
180 180 216 216 216 276 276
Page 15
6’ DIAMETER TANKS
8’ DIAMETER TANKS
9’DIAMETER TANKS
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Page 16
1-1
3
15’ DIAMETER TANKS 1-1
3
18’ DIAMETER TANKS 1-1
3
21’ DIAMETER TANKS 1-1
3
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Page 17
24’ DIAMETER TANKS 1-1
3
27’ DIAMETER TANKS 1-1
3
30’ DIAMETER TANKS 1-1
3
33’ DIAMETER TANKS 1-1
3
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Page 18
1-1
3
39’ DIAMETER TANKS 1-1
3
42’ DIAMETER TANKS
1-1
3
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Page 19
Weather Skirt & Cap Installation 12’ – 24’ DIAMETER TANKS
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Page 20
Roof Cap Hinge Installation 12’ – 24’ DIAMETER TANKS
NOTES: 1. Connect hinge (part B) (214002) to roof cap (214001) using (2) 5/16” x 3/4” HH bolt (290001) & 5/16” Hex Nut (290010). 2. Connect hinge (part A) (214003) to weather skirt (210196) using (4) 5/16” x 3/4” HH bolt (290001) & 5/16” Hex Nut (290010). 3. Assemble together using hinge spacer (214004) & 3/8” x 3 1/2” HH bolt (290012) & 3/8” Hex Nut (290014) as shown. www.qualitycontrolsteel.com (855) 412-0868
Page 21
Roof Safety Ring Installation 12’-24’ DIAMETER TANKS JIFFY CLIP #214434 (1 REQUIRED EVERY THIRD ROOF RIB) SAFETY RING SEGMENT
ROOF PANEL USE 5/16" X 1 1/4" [8 X 32] HEX HEAD BO LT W/SW GR8.2
3/4" STEEL CONDUIT COUPLER#290161
SAFETY RING SEGMENT (3/4" E MT CONDUI T)
SAFETY RING SEGMENT (3/4" E MT CONDUI T)
#12-14 X 3/4" [19] SELF-DRILLING FASTENER (2 REQUIRED PER CONNE CTION)
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Page 22
Roof Cap Assembly 27’ – 42’ DIAMETER TANKS
NEXT PAGE)
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Page 23
Roof Cap Assembly 27’ – 42’ DIAMETER TANKS
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Page 24
Complete Roof Cap Assembly 27’ – 42’ DIAMETER TANKS
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Page 25
Roof Support Ring Installation STANDARD ON 39’ & 42’ TANKS ONLY (Optional on other tank diameters)
TANK SIZE
NUMBER OF RIB BRACKETS
NUMBER OF SEGMENTS
NUMBER OF EXPANSION BOLTS
*LOCATION OF SUPPORT RING BRACKET
NUMBER OF SUPPORT RING CONNECTORS
ROOF SUPPORT RING ASSEMBLY
42’ 39’ 36’ 33’ 30’ 27’ 24’ 21’ 18’
36 36 36 36 36 36 24 24 24
7 6 6 6 6 5 5 4 3
2 1 1 1 1 1 1 1 1
7 7 6 5 5 4 4 4 4
5 5 5 5 5 4 4 3 2
STANDARD STANDARD OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL OPTIONAL
*NUMBER OF HOLES FROM BOTTOM OF ROOF SHEET
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Page 26
Roof Support Ring Details TO TIGHTEN AFTER ASSEMBLY, MOVE NUTS TO BOTH ENDS SUPPORT RING SEGMENT
SUPPORT RING SEGMENT
1111111111111
SUPPORT RING EXPANDER BOLT & NUT PART #211186 (SEE PLAN FOR LOCATION)
DETAIL 'A' EXPANDER BOLT
#12-14 X 3/4" (5.5 X 19) SELF-DRILLING
SUPPORT RING CONNECTOR PART #214953
@@ t...
FASTENER (8 REO D PER CONNECTOR)
@
II
SUPPORT RING SEGMENT
_)
DETAIL 'B' RING CONNECTOR SUPPORT RING SEGMENT
SUPPORT RING BRACKET PART #214359
'C'
DETAIL SUPPORT RING BRACKET TO ROOF CONNECTION
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Page 27
Bolt Schedule INSTRUCTIONS FOR BOLT PLACEMENT ON STEEL TANKS WITH ROOFS Anchor Clips: (Refer To Page 29) - Insert 3/8” diameter x 1” Button Head Bolt from inside the tank. - Use 3/8” Metal-Backed Sealing Washer between the tank wall and bolt head. - Fasten with 3/8” Hex Nut. Clamp Strip to Top Wall Sheet: - Insert 5/16” diameter x 1 1/4” Hex Head Bolt from inside the tank. - Use 5/16 Metal-Backed Sealing Washer between wall sheet and Hex Nut. - Fasten with 5/16” Hex Nut. All Vertical Seams and All Other Horizontal Seams: - Insert 5/16” diameter x 3/4” Truss Head Bolt from inside the tank. - Fasten with 5/16” Hex Nut. For Wall Sheets 15 Gauge and Thicker: - Insert 3/8” diameter x 1” Button Head Bolt from inside the tank. - Use 3/8” Metal-Backed Sealing Washer between the tank wall and bolt head. - Fasten with 3/8” Hex Nut. NOTE: Upper wall sheet ring should always overlap the wall sheet ring below it. IT IS NOT NECESSARY TO FIELD DRILL the bottom seam of the upper wall sheet to match the extra holes on the top seam of the wall sheets below. Roof Panel Bolts: (Refer To Pages 13-19) - Insert 5/16” diameter x 1 1/4” Hex Head Bolt from the top of the Roof Panel. - Fasten with 5/16” Hex Nut. - For 6’ & 9’ Dia. Tanks use 5/16” x 3/4" Hex Head Bolt. - Fasten with 5/16” Hex Nut. Roof Center Clips and Rib Clips To Roof Panels: (Refer To Pages 13-19) - Insert 5/16” diameter x 1-1/4” Hex Head Bolt from the top of the Roof Panel. - Fasten with 5/16” Hex Nut. Roof Center Clips and Rib Clips To Wall Sheets: (Refer To Pages 14, 16-19) - Insert 5/16” diameter x 3/4” Hex Head Bolt from outside the tank. - Fasten with 5/16” Hex Nut. Access Panel: (Refer To Page 30) - Use standard wall sheet bolts and nuts. DESCRIPTION 3/8" X 1" BUTTON HEAD BOLT GR. 8.2 3/8" X 1 1/4" BUTTON HEAD BOLT GR. 8.2 5/16" X 3/4" HEX HEAD BOLTS W/ SEALING WASHER GR. 8.2 5/16" X 3/4" TRUSS HEAD BOLT W/ SEALING WASHER GR. 8.2 5/16" X 1 1/4" HEX HEAD BOLT W/ SEALING WASHER GR. 8.2 5/16" METAL-BACKED SEALING WASHER 3/8" METAL-BACKED SEALING WASHER 3/8" JAM NUT
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Page 28
Anchor Clip to Bottom Wall Sheet Attachment
Vertical Seam Offset for Wall Sheets Do NOT line up vertical seams on adjoining wall sheets
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Page 29
Access Panel Installation Install access panel before hanging main liner inside tank.
22” 35”
WALL SHEET BOLT
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Page 30
Inlets, Outlets & Overflow Pipes Water Inlet-Outlet Requirements Every QUALITY CONTROL STEEL water steel tank has mandatory inlet-outlet and overflow requirements. Each tank must be equipped with a water inlet-outlet pipe and an overflow pipe. Pipe sizes, connections and any controls should be designed by a local engineer retained by the tank purchaser. Several drawings of recommended piping connections to the QUALITY CONTROL STEEL tank liner are shown below. A discharge outlet and silt stops may be needed. Design of inlet and outlet is the responsibility of purchaser’s engineer. An overflow pipe is required. Warning: Do not leave any portion of flexible liner unsupported at flange connection.
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Page 31
PENETRATIONS TH ROUGH TANK F LOOR(FOUND ATION)
PIPE INS TALLED TH ROUGH FLANGE LINER BOOT
STAINLESS CL A MP
SEAL PLATE PRELINER
PRELINER
COUPLING
INNER FLANGE
M AIN LINER
PRELINER
OUTER FLANGE
OUTER FLANGE
LINER BOOT
M AIN LINER
INNER FLANGE PRELINER
M AIN LINER
OUTER FLANGE
OUTER FLANGE
PENETRATION
PRESSURE PIPE
WITH SEAL PLATE
FLANGE SET
TH ROUGH FLANGE SET
PENETRATIONS TH ROUGH TANK WALL
PRELINER
PRELINER
STAINLESS CLA MP
STAINLESS CLA MP
LINER BO OT
LINER BOOT
PRELINER
INNER FLANGE
M AIN LINER
LINER BOOT PIPE EXTERNALLY SUPPORTED
LINER BOOT WITH FLANGE SUPPO RT AT TANK WALL
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OUTER FLANGE
M AIN LINER
PIPE INS TALLED TH ROUGH FLANGE
INNER FLANGE
SEAL PL ATE
M AIN LINER
PRELINER
PRELINER
Liner Penetration Options
M AIN LINER
OUTER FLANGE
OUTER FLANGE WITH SEAL PLATE
M AIN LINER
OUTER FLANGE
PEN ETRATING FLANGES
M AIN LINER
OUTER FLANGE
PRESSURE PIPE TH ROUGH FLANGE SET
Page 32
Installation of Penetration Liner Boots in Concrete Floor
1
2
3
4
5
6
7
Note: Pipe and couplings indicated in this discussion are not supplied with the penetration liner boot kit. The project designer should specify and supply the desired flanges. 1. Cut off under floor piping and install either a glue socket coupling or threaded coupling onto pipe. The top of the coupling should be flush with the top of the finished concrete floor. 2. Install the preliner and main flexible membrane liner into the tank and set liners into final position. 3. Cut hole through liner and preliner to be the same size as the outside diameter of the coupling. 4. Glue or thread the standpipe into the coupling. 5. Slide the penetration liner boot over the coupling with the flange of the boot toward the floor. 6. Glue or weld the flange of the boot to the liner. Apply glue to both the liner and the underside of the flange and let glue dry to slight tackiness before pushing flange onto liner. 7. Glue or use quality control steel patent pending product1A to seal inside of boot nozzle to pipe wall. Install stainless steel screw clamp around exterior of nozzle to hold nozzle to pipe. Do not over tighten clamp and cut the nozzle material
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Installation of Penetration Liner Boots in Corrugated Tank Side Wall
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Note: Flanges and pipe indicated in this discussion are not supplied with the penetration liner boot kit. The project designer should specify and supply the desired flanges. 1. Layout the location of the penetration onto tank wall with a drawing compass and cut a clearance hole for the pipe. 2. Mark the location of the flange attachment bolts and drill the holes. 3. Bolt a pair of flanges together with one flange inside of the tank and another flange outside of the tank. 4. Install the preliner and main flexible membrane liner into the tank and set liners into final position. 5. Cut hole through liner and preliner and install pipe through flanges and extend pipe into the tank. 6. Slide a liner backing plate onto the pipe from the inside of the tank. Slide the penetration liner boot over the pipe with the flange of the boot toward the wall. 7. Glue or weld the flange of the boot to the liner. Apply glue to both the liner and the underside of the flange and let glue dry to slight tackiness before pushing flange onto liner. 8. Glue or use quality control steel patent pending product1A to seal inside of boot nozzle to pipe wall. Install stainless steel screw clamp around exterior of nozzle to hold nozzle to pipe. Do not over tighten clamp and cut the nozzle material.
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Installation of Penetration Flanges in QUALITY CONTROL STEEL TANKS A penetration flange set consists of an outer flange and an inner flange or seal flange, a gasket, hex head cap screws and seal washers. Most sets are produced from schedule 80 PVC fittings unless otherwise specified for a particular project. Wall Mounted Flange Installation for Overflow or Inlet or Outlet 1. The outer flange is tapped to receive bolts inserted through the wall of the tank and also tapped to receive bolts from the inner flange or seal plate. 2. Locate the desired penetration location and mark the center of the hole. 3. Drill or cutout a hole through the tank wall that is large enough to allow the glue neck of the outer flange to pass through. 4. Place the outer flange neck into the hole from the outside of the tank and locate the bolt holes onto the tank wall. 5. Remove the outer flange and drill clearance holes for the wall mounting bolts. 6. Insert the outer flange neck into the hole in the tank wall from the inside of the tank. 7. Insert the wall mounting bolts from the outside of the tank wall through the tank wall and thread them into the tapped holes in the outer flange. This will keep the outer flange in place during liner installation. 8. Apply a bead of silicone sealant around the cutout at the glue neck of the outer flange on the outside of the tank wall to improve the appearance of the penetration. 9. After the preliner is installed inside the tank, cut the preliner back away from the face of the outer flange and tape the preliner to insure that is does not get between the flange face when the main liner is installed. 10. Install the main liner and check to be sure that it is hanging smoothly over the face of the outer flange. 11. Locate a tapped bolt hole in the outer flange through the main liner and cut out a hole in the liner to allow the bolt to pass through. Thread the bolt into the tapped hole a few turns only. 12. Smooth the liner across the face and locate another hole opposite of the first hole and repeat the procedure to install a second bolt. 13. Continue to locate and cut bolt holes in the liner and install bolts until all of the inner flange bolt holes have been cutout. 14. While bolts are still in place cut-out the center hole in the liner. 15. Remove the flange bolts. 16. Lift the liner away from the face of the outer flange and apply a bead of sealant to the outer flange face around each bolt hole and around the inner and outer perimeter of the flange face. 17. Lightly press the liner against the sealant and the outer flange face. 18. Apply another bead of sealant onto the liner. 19. Place the gasket onto the sealant. 20. Apply another bead of sealant onto the gasket. 21. Install sealing washers onto the flange bolts. 22. Place the inner flange against the gasket and liner and install the flange bolts. 23. Tighten bolts in a pattern working across the flange face until firm. Do not tighten to torque values that are normally used for flange connections. 24. Smooth and feather all sealant squeeze-out.
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Bottom Mounted Flange Installation for Drain, Overflow, Inlet or Outlet 1. The outer flange is tapped to receive bolts from the inner flange or seal plate. 2. Cutoff the pipe that extends through a blockout in the foundation below the top surface of the foundation. The pipe needs to be cut to allow the face of the outer flange to be flush with the top of the foundation after the flange is attached to the pipe. 3. Attach the outer flange to the pipe as required. 4. Tape the face of the flange to prevent damage to the flange face and to prevent debris from entering the tapped holes. Tape under the flange to keep the tapped holes clean also. 5. Backfill the blockout hole around the pipe and flange and top with cement. It is important to finish the cement around the flange to make a smooth transition. 6. After the preliner is installed inside the tank, cut the preliner back away from the face of the outer flange and tape the preliner to insure that is does not get between the flange face when the main liner is installed. 7. Install the main liner and check to be sure that it is hanging evenly around the tank and that the liner is pushed out all around the bottom to be a smooth surface at all penetrations. 8. Locate a tapped bolt hole in the outer flange through the main liner and cut out a hole in the liner to allow the bolt to pass through. Thread the bolt into the tapped hole a few turns only. 9. Smooth the liner across the face and locate another hole opposite of the first hole and repeat the procedure to install a second bolt. 10. Continue to locate and cut bolt holes in the liner and install bolts until all of the inner flange bolt holes have been cutout. 11. While bolts are still in place cut-out the center hole in the liner. 12. Remove the flange bolts. 13. Lift the liner away from the face of the outer flange and apply a bead of sealant to the outer flange face around each bolt hole and around the inner and outer perimeter of the flange face. 14. Lightly press the liner against the sealant and the outer flange face. 15. Apply another bead of sealant onto the liner. 16. Place the gasket onto the sealant. 17. Apply another bead of sealant onto the gasket. 18. Install sealing washers onto the flange bolts. 19. Place the inner flange against the gasket and liner and install the flange bolts. 20. Tighten bolts in a pattern working across the flange face until firm. Do not tighten to torque values that are normally used for flange connections. 21. Smooth and feather all sealant squeeze-out.
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Venting A suitable roof vent shall be installed on any tank that may experience negative and positive pressures due to the inflow or outflow of water. The vent or vents should be installed in the roof and shall have the capacity to allow the passage of air, to insure that at the maximum possible rate of the water, either entering or leaving the tank, excessive pressure will not be developed. THE OVERFLOW PIPE SHALL NOT BE CONSIDERED A TANK VENT.
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Liner Protection The liner is durable and will provide many years of service if installed and maintained properly. The liner will NOT withstand normal foot traffic during installation and routine cleaning. The following precautions are recommended when working inside a tank or walking on the liner. 1.
Do not remove the liner from its carton until it is to be installed. Do not cut carton with a knife. Avoid dropping tools or sharp objects on the liner. Do not drag liner excessive distances over floor as the scrim will be exposed and lead to “weeping� type liner leaks.
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All personnel installing and maintaining liner should do so in bare feet or thin stockings. In no case should personnel enter tank, beneath liner, or inside liner with shoes or boots on. Wearing shoes may introduce foreign matter which could perforate the flexible liner. In addition, personnel working in bare feet can feel foreign matter that may be remaining on the foundation before it can damage the liner.
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Access to the tank interior through center hatch or additional access manhole may be made with an extension ladder with padded feet. Use of a rope ladder suspended from the hatch opening (See the figure below) is highly recommended. Permanent interior ladders must be designed to be retractable and equipped with proper cushioning on the bottom end of the ladder.
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Periodic entry between the steel tank and liner, for the purpose of inspection, repair, or readjusting sand overlay, may be made through sidewall wall sheets.
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An exterior ladder can be supplied (optional). Ladder extends to the top of the foundation.
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LINER INSTALLATION PRECAUTIONS 1. Do not open liner package with a knife. 2. Avoid dropping tools or sharp instruments on the liner. 3. ALL PERSONNEL INVOLVED IN LINER INSTALLATION MUST DO SO IN BARE OR STOCKING FEET. 4. QUALITY CONTROL STEEL tank liners are manufactured oversize so that there is plenty of slack. It is important, however, to see that no strains develop in the liner. To avoid strains, see that there is no shortage of liner material around the inside bottom perimeter.
INSTALL LINER HANGER BRACKETS The liner hanger brackets should be installed onto the top of the top tank wall sheet before the roof is installed. On QUALITY CONTROL STEEL tanks without rafters the bracket can simply be pushed by hand over the top edge of the wall sheet. On QUALITY CONTROL STEEL tanks with rafters it is necessary to drill 2 holes and bolt each liner hanger bracket to the tank wall.
INSTALL MAIN LINER WITH POLY ROPE IN HEM Place the folded main liner into the tank and open it up until the bottom of the liner is approximately in place in the bottom of the barrel. A rope has already been installed in the top hem at the factory but the ends of the rope are loose. Find the two stainless steel screw type hose clamps in the hardware kit. Smooth any wrinkles out the top hem so that the rope is evenly distributed around the top of the liner. Bypass the two ends of the rope and install the two hose clamps onto the rope to create a continuous rope around the top of the liner. Lift one side of the liner up to a liner hanger bracket. Make a 2� long horizontal slit in the liner just under the poly pipe and hand the liner onto the liner hanger bracket. Move 180 degrees across the barrel and repeat the steps. Then go 90 degrees left and then 90 degrees right and hang the liner and continue to divide spaces until the liner is suspended from all of the liner hanger brackets.
INSTALL MAIN LINER WITH POLY PIPE IN HEM (ALTERNATE) Place the main liner into the tank and open it up until the bottom of the liner is approximately in place in the bottom of the barrel. Find the hem in the top edge of the liner and insert the poly pipe into the hem all around the top edge. Join the poly pipe together with a coupler and hose clamps. Lift one side of the liner up to a liner hanger bracket. Make a 2� long horizontal slit in the liner just under the poly pipe and hand the liner onto the liner hanger bracket. Move 180 degrees across the barrel and do the same. Then go 90 degrees left and then 90 degrees right and hang the liner and continue to divide spaces until the liner is suspended from all of the liner hanger brackets.
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Liner Inspection Just prior to filling the QUALITY CONTROL STEEL Water Steel tank, the liner must be inspected to insure that the liner floor has been pulled up to the wall so that there will be no “bridging” at intersection of wall and floor. A sloping floor may cause the liner to creep away from the wall between the time of installation and filling of the tank.
Tank Disinfection Tank Disinfection – For Potable Water Steel tanks Only The finished QUALITY CONTROL STEEL Water Steel tank must be disinfected by the purchaser or installer prior to use. Finished structure must be disinfected in accordance with AWWA D105, Method No. 3.
Chlorination Method 3 Water and chlorine shall be added to the storage facility in amount such that initially the solution will contain 50 mg/L available chlorine and will fill approximately 5% of the total storage volume, and this solution shall be held in the storage facility for a period of not less than 6 hours. The storage facility shall then be filled to the overflow level by flowing potable water into the highly chlorinated water, and shall be half-full for a period of not less than 24 hours. All highly chlorinated water shall then be purged from the drain piping. Then, subject to satisfactory bacteriological testing and acceptable aesthetic quality, the remaining water may be delivered to the distribution system. www.qualitycontrolsteel.com (855) 412-0868
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Care of Liner Cleaning the Liner The surface of the liner is relatively smooth and can be cleaned with a light brushing and pressure spray (water) wash down. The liner can easily accept sweeping, foot traffic and agitation necessary to remove any silt and sludge collected in the tank. Remember, all personnel entering tank must be in bare feet or thin stockings…no shoes or boots. Sanitizing the liner with chlorine wash applied with spray equipment has no negative effects on the liner. Liner Repair In the event of a cut or damage to the liner, repair can be accomplished by chemically welding a new piece of vinyl over the affected area, using a large second ply over the first patch. This repair may be done to the inside or outside of the liner sheet. Proper repair instructions are provided in the patching kit. All repairs shall be accomplished by personnel in bare feet or stocking feet.
Water Level Control and Monitoring Water level controls may be installed inside the tank. Control wires for these devices should exit the tank at the eave or from a junction box mounted on the roof. www.qualitycontrolsteel.com (855) 412-0868
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Ice Formation The water in any storage vessel or tank may freeze when subject to temperatures below the local freeze point for extended periods of time. Ice formation inside of a water steel tank is not uncommon but the following precautions should be taken to reduce the possibility of ice damage to the tank structure, lining or controls: 1. Water level controls must be installed in such a manner that the controls will continue to function even when ice may encase the level control sensor. 2. Water outlet pipes should be installed through the bottom of the tank, rather than through the side wall of the tank. The under tank piping should be buried below the local frost level to prevent rupture of the piping from a freeze. 3. Water fill pipes should be insulated or equipped with drain down devices to prevent a rupture of the piping from freezing. 4. Top ice may form at the tank to roof junction. A formed steel ice breaker can be installed around the inside top perimeter of the tank wall to keep the top ice from damaging the liner. Tanks may be insulated to prevent internal icing problems. A QUALITY CONTROL STEEL tank can be easily insulated with the installation of foam insulation between the tank wall structure and the interior liners. This is an economical method as it eliminates the need for an external insulation jacket. CAUTION: WITHOUT SOME EXTERNAL HEAT SOURCE, WATER WILL EVENTUALLY FREEZE EVEN IN INSULATED TANKS. With or without insulation, the ice problems can be avoided by the use of water heaters, aerators or recirculation. Water heating may present viable protection against ice formation. In the event that tank heating is chosen as the method to be used to prevent ice formation, follow the recommendations of the National Fire Protection Association Standard 22, Standard For Steel tanks For Private Fire Protection, Chapter 10. A licensed engineer, with experience in freeze protection for the tank site, should be employed to design any freeze prevention plan. WARNING: FAILURE TO ADEQUATELY PROTECT AGAINST ICE FORMATION INSIDE THE TANK SHALL VOID THE WARRANTY ON THE FLEXIBLE MEMBRANE LINER. FAILURE TO PROTECT ALL PENETRATIONS FROM FREEZING SHALL VOID THE WARRANTY ON THE TANK STRUCTURE.
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