When procuring a water storage tank, the process of configuring and selecting the appropriate tank typically initiates early in the project design phase. Considerations such as the construction schedule and overall project expenses are factored in when seeking and securing available funding. Given that many municipalities depend on a single water storage source, the tank’s design significantly influences meeting both current and future community needs.
Several critical factors, including community water demands, site conditions, pressure requirements, long-term maintenance considerations, accessibility, and overall expenses, must be evaluated during the final selection of the tank configuration process.
For municipal water storage applications, three types of liquid storage tanks are commonly utilized: glass-coated bolted steel, welded painted steel, and concrete.
1. Manufacturing Process
The technology and manufacturing methods utilized for this equipment distinguish it from painted steel or concrete structures. Unlike field-manufactured products such as painted steel or concrete tanks, the factory manufacturing process eliminates uncontrolled variables. Factors like worker experience and extreme climatic conditions, which can significantly affect in-field manufactured products, have minimal impact on the glassing process. Additionally, since the tanks are manufactured in the factory and only require assembly of components in the field, they can be erected throughout the year.
2. Coating
All storage tanks undergo coating processes, which include options such as paint, concrete, or glass. Glass coatings offer unique advantages due to their impermeability and properties.
The glass coating process begins with a glass frit, which is mixed with other minerals and water to create a liquid slurry. This slurry is then carefully sprayed in precise amounts and thicknesses onto pre-cut and rolled steel sheet panels, which have undergone punching, grit-blasting, and cleaning processes.
In contrast to coatings for other tanks that rely on a mechanical bond with the underlying material, the chemical bond strength of glass coatings is significantly higher. This chemical bond prevents the undercutting of the coating, which could otherwise lead to corrosion spreading on the primary steel material. To illustrate, imagine a scratch on a car. With a coating that only has a mechanical bond, corrosion would occur upon steel exposure. If left untreated, this corrosion would extend beneath the surrounding painted surface, compromising the remaining coating.
Common signs of this issue include raised bubbles, spreading rust, and weakened substrate. However, the chemical bond of a glass-fused-to-steel coating prevents corrosion from spreading even if the coating is compromised.
3. Tank Construction
During the assembly of a glass-coated bolted steel storage tank, a jacking system is utilized. Initially, the tank’s top ring is assembled on the jacks, followed by the placement of the starter sheet (bottom ring), which is either embedded in the concrete foundation or constructed using a glass-fused-to-steel floor design. Subsequently, the tank’s roof is installed, and both the ring and roof are elevated using jacks. Each subsequent ring is then bolted together beneath the top ring, with a urethane sealant applied between the seams.
The tank construction follows a top-down approach, facilitating a safer and more efficient assembly process. Typically, the erection process is completed within a week or two, resulting in cost savings for the owner, especially when utilizing prevailing wages for onsite labor. Moreover, the manufacturer mandates that all construction crews undergo factory training and certification in the erection process, ensuring quality control during field operations.
4. Maintenance
Glass-coated bolted steel tanks offer a prolonged lifespan thanks to their permanent glass coating, eliminating the necessity for regular painting. These tanks are frequently favored in areas where a resilient and visually appealing appearance is sought after for the foreseeable future.
5. Flexibility
The bolted design and assembly process of this product provide significant flexibility. Unlike on-site manufacturing, which requires extensive staging areas, factory production eliminates this need. Typically, the tank can be constructed with a minimal cleared space of 6 to 10 feet around its diameter. This compact footprint not only saves considerable project costs but also reduces overall expenses associated with the tank. Additionally, the lightweight panels can be assembled manually without the requirement for cranes or specialized equipment, allowing installation in locations that might be inaccessible for other types of tanks.
6. Expandability
The design of the glass-coated bolted tank allows for vertical expansion. If community or industrial growth requires increased capacity, the tank’s jacking process provides a swift and cost-effective solution. A construction crew trained by the factory can readily carry out this process by dismantling the bottom ring from the original starter sheet, elevating the tank, and adding the required number of rings to accommodate the increased capacity. Crucially, when these tanks are expanded, there is no noticeable differentiation between the original and new panels.
Conclusion
When examining tank designs and materials, it’s vital to take into account factors such as initial construction costs, anticipated lifespan, and ongoing maintenance expenses. Evaluating long-term maintenance costs and the product’s life cycle is critical when selecting the most appropriate option for a specific project. As project funding may fluctuate due to various factors, conducting a thorough analysis of upfront expenses and potential future savings in maintenance costs can assist communities in determining the optimal product for their needs.
For further discussion on any of the topics covered here, feel free to reach out to our knowledgeable and friendly customer service team. We provide reliable services in Houston, Texas, and Long Beach, California, tailored to meet your needs.
Call Tanks Liners by American Tanks at +1 800 656 0167
Or email at info@americantankliners.com
