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Steel tonnage used (US tons):
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24" OD x 36" Reactor with Body Flange and Coil
ASME SEC8 DIV1
Our customer came to us to solve an issue for a process that he had where he would need an extreme amount of nozzles in a compact reactor. With all the nozzles on the 24” head, the vessel being stainless, half pipe jacket coil, and a body flange; we took the job knowing it would be a challenge. Without the capability of our shop and 3D modeling, this tank would have never been able to be built. The reactor was so busy; the top head lift lug was welded to a blind flange that was bolted to the agitator flange.
Our engineering team did an amazing job of working with the customer to manage the job and get the customer exactly what he wanted. The job started as most do with a sketch and a bunch of words on paper. From there our engineering manager worked closely with his team and the customer to create this vessel. There were challenges along the way, such as, overlapping flange planes and available space. Designs went back and forth with the customer, changing from a conventional jacket with internal baffles to a half pipe coil jacket. This was just the beginning.
Our production team faced its own challenges including sequencing, distortion, and complexity. We used our waterjetting capabilities to cut the holes in the head to minimize distortion. This was of great benefit as the holes were exactly where they should be as well as the cold process of the waterjet did not distort the head at all. In fact, the head without the nozzles was affectionately referred to as a “lady bug”. As anyone in the steel industry knows there are also certain nuances associated with half coil jackets, but compared to the head those issues seemed insignificant. The last real concern we had was welding the nozzles in the head as to not block welding of other nozzles. This was marked on the drawing by the production team and was followed without incident.
The most important part of creating any product for a customer is their complete satisfaction. In this regard the reactor shined through and through. We received e-mails complimenting the entire company for its ability to complete such a “nice looking”, technical and unique vessel. This project was one of the more challenging and also most rewarding projects in recent memory.
Product / project title:
Steel thickness (inches):
Six (6) PVC Reactor Condensers
Geismar Vinyls Company
ASME / TEMA
6” Thick Body Flanges
A large multi-national chemical manufacturer inquired for supply on a large project. The project entailed equipment to double the capacity of one of their product lines at one of its largest plants in the states. Due to the large scope of the project and the required plant shut-down, all facets of the operation needed to adhere to tight production schedules and timely deliveries of finished goods.
The scope of supply was for (6) identical 64" diameter Falling Film Condenser Reactor heat exchangers.
The assembled empty weight of each condenser was 23,000 lbs. The materials of construction for the process side of condenser were type 316L stainless steel. The shell portion was fabricated from carbon steel. Each condenser utilized well over 2000 tubes, with each tube seal welded to the tubesheet on each end before being expanded into serrated (grooved) tube holes in the tubesheet. The process side was designed for 200 psig and full vacuum, requiring the use of 6" thick body flanges and 3" thick tubesheets. The condenser was constructed per ASME Section VIII requirements as well as TEMA class 'R' (Refinery) design requirements and were stamped with the ASME Code 'U' designation for Unfired Pressure Vessels.
To complete the construction within the committed fabrication window mandated the use of over (40) welder/fabricators and a dozen engineers/foreman/quality control personnel.
Horizontal Diesel Storage Unit w/Pump and Generator House
One (1) of four (4) units built for the tracking industry, this 12,000 gallon double wall diesel storage tank, with engine/generator house bolted to a beam skid frame, has extended checkered plate platforms at each end and is put in service as a stand-alone energy source in remote areas. With power equipment installed, this unit can also be moved into areas hit with loss of power and used to support emergency units.
The pump house end includes an elevated engine/generator mounting platform, an integrated drip containment and lockable doors. The fill end has a 3" remote fill with limiter, vertical swing check, ball valve, cam lock adapter and drip pan. Also on fill end is a ladder and a power source cable holder. Included on both ends are sight gauges and light brackets.
This unit also includes an exposed open unistrut chase for an electric feed from the generator to the cable holder and is coated with an acrylic polyurethane.
Fueling Aviation Tanks (6)
Puma Energy Paraguay
Asuncion International Airport
Flameshield, UL 142; SwRI 97-04
Six tanks each 9 ft. diam. X 41.5 ft. long
119,448 (19,908 gallons each)
0.25” inner tank, 0.1875” outer tank
Six storage tanks each with a platform and ladder with a total storage capacity of 118,877 gallons (450 m3). The tanks are storing Jet Fuel A1 and Avgas. There is a single central platform with stairs (45°) at both ends of the platform.
The tanks are equipped with flanged connections ANSI B16.5 S150 RF, Threaded NPT (stainless steel) and inner piping (stainless steel) for Load, Suction, Normal Vent, Emergency Venting, Drainage, Manual Measurement, Interstitial Sensor, Measuring c/ Instruments and additional Manhole x24bul Ø600, Lifting lugs and metal saddles.
Exterior Surface finish: Blasting to near- white metal SSPC SP5, Epoxy base and termination with Polyurethane Enamel.
Interior Surface finish: Blasting almost white metal SSPC - SP5, Epoxy suitable AVGAS / JETFUEL, 300¼mm thickness.
Includes the following accessories:
Normal Vent Pipe with Pressure / Vacuum Valve and Block arrester, Emergency Vents Ø10" Level Meter w / overfill alarm (for 2 tanks), Floating Suction and manual pump for taking fuel sample.
APPLIED STANDARDS: Flameshield, UL 142; SwRI 97-04.
STAIRS AND PLATFORM WITH ACCESS TO SIX TANKS:
Formed by a superior platform linked to the four tanks; double set of stairs 45° (access and egress at each end of platform). Platform constructed of carbon steel, profiles, tubes and standardized structural platen.
Fitted with guard-feet, intermediate rail; FRP grating floor plates and Inspection manhole covers. Staircase built in carbon steel C profiles, tubes and standardized structural platens. Grating Steps metal (750mm width). Equipped with supports and termination for bolted assemblies on tanks and floor.
Surface finish, Blasting Epoxy base and finishing with Enamel Polyurethane.
18,000 Gallon Fructose Shipping Container Tanks (6)
Sea Star Line LLC
11’ -0” H, 53’ -0” L
108,000 Total (18,000 each)
These six (6) 18,000 Gallon Fructose (Liquid Sugar) Shipping Container Tanks are the first built of their kind. While there are many Fructose Shipping Containers that are built and in operation at 40’ long, these six (6) tanks were built to the largest container size at 53’ long. The overall dimensions are 8’-6” wide X 53’-0” long X 11’-0” high. The units ship Fructose from Jacksonville, FL to Puerto Rico to be used in the production of soft drinks. These tanks will eventually reside in the first ever Compressed Natural Gas (CNG) powered cargo ships that are under construction in San Diego, CA. The new ships are due to be delivered to the owner in the spring of 2015.
The tanks are constructed with 304 polished stainless steel and insulated against heat loss with Polyisocyanurate (Poly-Iso) insulation and protected with PVC skin. When these tanks are installed in the new CNG powered ship, they will stack on top of one another three high! The design of the tanks and the ship requires that the load be supported at the four corners only. So, the bottom tank not only has to support its load, but also the two tanks that are stacked above it! Massive 8” X 8” X 5/8” thick square columns are in the corners and 24” tall I-Beams run the length of the assembly to carry the load within the truss frame designed. Extensive stress analysis was undertaken so that under a full load the entire unit would deflect less than 1”.
The six tanks were initially installed in the third level below deck on the owner’s existing cargo ship. When they are removed and installed on the new CNG powered cargo ships, the existing tank will be decommissioned.
SS Caustic Tank w/basin & skids
8000 gallon above ground single wall horizontal tanks with basin); 96" x 22' long; made from 316L stainless steel, 1/4" thick. Flat flanged heads with internal reinforcement, 1/4" thick shell with all seams butt-welded, inside and outside; (2) 316L SS UL approved welded saddles with re pads; includes 28" man-way, rear access ladder, (6-8) 2" 150# flanges, 2" schedule 10 316L piping from pump platform to 150# flanged ports on top of tank and (1) 8" schedule 10 flanged 180 degree goose neck vent with catch basin and rain hood.
Basin for the above tank is approximately 10' wide x 4' deep x 28' long; constructed with 1/4" thick 304 stainless steel, seal welded butt joints inside and outside; reinforced by perimeter 3" (304ss) angle iron and 1/4" thick internal buttresses; tank fastened to basin supported by 6" A36 beam grid and full length 6" schedule 40 A53 pipe hooks; carbon steel members coated with Carboline epoxy primer plus polyurethane top coat system.
The entire structure was covered and used as a processing tank for special field work that I was not permitted to discuss.
See description below
Seven (7) shop built atmospheric tanks for waste water treatment facility with sizes ranging from 78" to 162" diameter x 22'-10" to 35'-0" overall heights. Work scope included manufacturing the tanks performing shop interior and exterior coatings, and field installation at very compact site under "high hazard" working restrictions. The existing facility had to remain in service 24/7 without disruption. Project completed on time without safety incidents.
CMCO 14-17469 / Protected Generator Base Tank
4’H x 12’W x 46’L
CMCO 14-17469 / Protected Generator Base Tank with Enclosure
This project was for three units placed into service in Cary, North Carolina. The three fuel tanks provided are steel, above ground tanks used as generator set base tanks. The tanks are protected generator tanks incorporating both secondary containment and a monolithic fire insulation system. These tanks are STI licensed and built in accordance with UL2085 standard. The tanks are built utilizing the STI internal support design. The monolithic insulation was pumped into the tanks. The tank assemblies were constructed using 0.25” thick steel plate.
Each tank included the following features: Fuel fill assembly with spill bucket and overfill prevention valve, low and high fuel level alarms, leakage detection alarms, ports for automatic filling from remote location, and all required vents.
Each tank assembly supports a diesel powered generator set with unit mounted radiator and a protective steel enclosure around the equipment. The tank support beams are equipped with flooring platforms to allow walking and servicing around critical areas of the generator set.
The generator sets are prime power rated and produce 2,725 kW of continuous electric power. The generator sets include service entrance rated circuit breaker protection devices and all engine safety, control, and alarm devices.
The protective enclosures are constructed from a minimum of 14 GA. Galvannealed steel. The enclosures are equipped with service and maintenance access doors. Each enclosure is insulated and is equipped with heating and ventilation systems designed to provide adequate cooling for the generator set when exposed to high ambient temperatures. The enclosures provide sound attenuation, which reduces the sound level of the generator set to 80dB(A) when operating at full load. Each enclosure accommodates an interior mounted exhaust silencer, engine starting system and batteries, and electrical distribution system to power lights, receptacles, heaters, electrically operated air dampers, and ancillary items. Steps and platforms were provided to allow egress from grade to the interior of the enclosures.
These packages were evaluated by a licensed Professional Engineer and designed to withstand 150 MPH wind loads and seismic loads encountered at the project location. Each of the three packages were shipped to the job site in three major components for final assembly at the job site. The total assembled packages weigh 154,000 Lbs. each. All three units were installed nearby to each other in a courtyard. The durable and strong steel construction is utilized to provide years of protection to the valuable equipment.
Gallo Spirits 50,000 Gallon Tanks (3)
E. & J. Gallo Winery
150,000 (50,000 each)
Three 50,000 gallon tanks, with cone bottom and self-supporting cone roof top, were constructed of Type 304L stainless steel to the stringent quality requirements of a major central California beverage producer. The tanks were designed per API 650, including Annexes E, F, S, and V, for low pressure and partial vacuum. The tanks are designed for containment of high proof alcohol spirits products.
Unlike most API 650 tanks which are field erected, these 304 Stainless tanks were built from the top down with a total of 10 one-piece shell rings of 48" wide stainless plate. These rings were rolled to the precise diameter and carefully assembled and welded with full penetration welds to meet the demanding dimensional tolerances of the customer. All weld seems were ground and polished to a 120 grit abrasion finish with no surface finish exceeding a 45-60 Ra, maximum. Built in the shop, these tanks also required precise fabrication and assembly of the cone bottom to assure proper interface to the cone down concrete foundation provided by the owner.
In order to deliver these tanks from the shop, a specially designed transport trailer was designed and constructed to carry these tanks. The trailer is designed to stretch to a maximum length of 68 feet to accommodate the height and length of the tanks. All three tanks were transported via CHP escort over 225 miles from the fabrication shop to the winery facility in Modesto California.
St. Helena, CA
0.135 - 3/16”
In the process of producing red wine, extraction of color and tannins is a vital step. Under traditional winemaking procedures, this extraction is time consuming. A process developed in Europe, Flash Détente now allows the winemakers to extract the desirable compounds from the skins prior to fermentation, a step that reduces cycle time and increases product throughput. Flash Détente is the current version of the traditional thermovinification method. In this method, the crushed and de-stemmed grapes are rapidly heated to around 180°F, then the heated grapes are processed in a vacuum flash cooling system where the temperature is rapidly lowered to 86°F. The rapid cooling sequence causes an intercellular explosion in grape skins that produces the desired color and characteristics in an improvement over the traditional thermovinification method.
In order to process grapes in the Flash Détente process, the grapes must be processed in a mixer tank capable of maintaining a homogeneous gelatinous emulsion of the juice and solids. This tank was specially designed to accommodate a high torque, low speed internal mixer. To interface with existing winery equipment, this tank was required to be mounted on legs at 8 feet above the floor.
The tank is located in a region subject to high seismic loads, so a substantial foundation, anchorage and support structure was required to resist the ASCE 7 design loads. Additionally, the tank must support the substantial mixer loads, both gravity and torque loads. The support of the mixer and mixer shaft required close tolerance fabrication of the mixer support structure and guides. The tank is constructed entirely of Type 304 stainless steel.
Huntsville Utilities Monte Sano Tank Modification
The Huntsville Utilities East Governors tank began its life in 1974 as a much-needed water source for residential areas in the surrounding valley. The plan for the water tank was approved by the City and construction began on the 40’ tall, 1.5 million gallon water storage tank. Once construction complete, protest arose because the tank would block the view from a scenic overlook planned for a site just across the highway. After much political wrangling, an agreement was reached: the water tank would be shortened so that it would not block the view from the proposed scenic overlook.
The top two shell rings of the tank were removed, reducing the capacity to just under 1 million gallons, and reducing the height of the tank by about 16’. The “new” tank was 24’ tall with a capacity of 900,000 gallons. For the next 40 years, the tank served the surrounding communities, but it continued to be problematic. The reduced capacity and loss of pressure led to operational difficulties and inefficiencies. As more homes were built in the tank’s service area, Huntsville Utilities had to pump water to a higher tank and, during periods of peak demand, the water had to be regulated back down to the East Governors system.
Several years ago, the tank overflowed as the result of an operational error. The overflow damaged the tank’s rafter system. When the Utility began to evaluate the cost and scope of replacing the damaged roof, they went through Huntsville’s Locations, Character and Extent review process (put in place as a result of the 1974 water tank controversy) to seek permitting for a tank modification project. The review found that there was a real need for additional capacity and that adding the 16’ feet back to the tank would not significantly impact the view from the scenic overlook or the road.
Huntsville Utilities selected a tank contractor who offered a design solution that would address the damaged roof and provide a more aesthetically appealing tank, even at the increased height. The contractor suggested a design for the modification project that would provide the increased capacity the Utility needed, and would allow for more efficient use of the available height and ensure the long-term integrity of the tank’s interior. The tank builder proposed a custom-designed knuckle umbrella roof, which would permit maximum usable water storage space, and reduce the number of potential corrosion points inside the tank.
The tank contractor cut the existing tank down to expose the shell and prep it for the addition of two new shell rings. The new shell rings were added, and the new knuckle umbrella roof was constructed. The tank builder installed a second manway, new removable vent, ladders, handrails and fittings. The modifications expanded the tank’s capacity to 1.5 million gallons, and increased its height to 40’ – the original capacity and height of the 1974 design. The rounded edges of the roof’s exterior give the tank a cohesive, smooth, more visually appealing look that does not detract from the view of the valley below.
The interior coating system is a solvent free single coat epoxy resin that provides outstanding corrosion protection. The knuckle umbrella roof design works holistically with the paint system to maintain a clean, corrosion free environment. The exterior paint is a low gloss acrylic polyurethane designed to resist stains and retain color. The two-component high gloss fluorourethane finish coating provides enhanced color and long term gloss retention. The tank contractor was able to bring these important aesthetic and operational changes to the East Governors water tank within a short timeframe; the modifications were completed and the tank was painted and returned to service in twelve weeks. Today, the East Governors water tank is visible below the scenic overlook. The surrounding trees are higher than the top of the tank, and the view of the valley beyond those trees is even more magnificent than it was in 1974.
Village of Matteson, IL Elevated Tank Raise
500,000 Water Spheroid / Village of Matteson, IL
157’ -11 5/8”
63’ -1 5/32”
The Village of Matteson, Illinois ("the Village”) was facing a dilemma in its water system. The Village’s East Tank and West Tank were not operating effectively due to elevation differences between the two tanks which was causing low operating pressures, fire flow issues, water conservation issues and water main breaks on the Westside of the Village. Rather than opting to purchase and erect a new elevated water tank, the Village decided to modify its existing West Tank by adding approximately19 feet of stem to the tank’s support structure. The successful “raising” of the tank allowed both the East and West tanks to operate as one homogeneous water zone thereby alleviating the water pressure, fire flow and water loss issues….and this unconventional water system upgrade saved the Village approximately $800,000 compared to the cost of new construction.
The West Tank was located adjacent to Woodgate Elementary School (“Woodgate”), where an opportunity to give back to the community presented itself. The Village, the contractor and other outside consultants who participated in the project met with and presented specifics on the project to students at Woodgate. The goal was to further educate the students and staff on the importance of Municipal Government, Public Works Engineering and Contracting. The team developed a curriculum for the teachers which included estimating distances, understanding water pressure, safety education, crossword puzzles, word searches and quizzes related to Public Utilities. The entire school had an opportunity to be present during the actual raising of the tank and to work in the mobile command center. The command center included blue prints, model tanks and cranes which gave tangible opportunities for students to engage real world examples of the construction and engineering process. In addition, the entire school received project/school shirts and hardhats.
Overall length (feet):
Steel tonnage used (us tons):
Green River Filtration Facility
City of Tacoma
6 to 108
0.25 to .59
Our company supplied the carbon steel piping for a new water filtration plant for the City of Tacoma, Washington.
This project included 3500 feet of 36"pipe, 3000 feet of 42"pipe, 1200 feet of 54" pipe, 300 feet of 72" pipe, 900 feet of 84" pipe and 400 feet of 108" pipe. The pipe wall thickness ranges from .25" to .59". The project also had various others sizes and lengths that were too numerous to list.
The pipe on this project was polyurethane coated and lined with a few areas of above ground piping that were primer coated. Heat shrink sleeves were used by the contractor to protect the field welds before they were buried.
City of Austin, Texas
The 36" Backwash Supply Header was provided inside a very tight filter gallery. What makes this a particularly difficult configuration is that the header branched off to six filters and connected to 12 flanged wall thimbles, already cast in the wall. As the 36" branched off from the main header, it was necessary to vary the location of all 12 connections in order to match the varying locations of each thimble. No two dimensions were the same.
In addition, it was necessary to vary every flange to match existing condition of plumbness, squareness and "two hole" for the cast wall thimbles.
After careful coordination with the contractor and fabrication, the line fit up without any problems.
SE Louisiana Urban Flood Control Project - Harahan Pump Station
US Army Corps of Engineers – New Orleans District
0.5 to 1.75
This pipe project is a key component of the Southeast Louisiana Urban Flood Control Program (SELA), which congress created after the catastrophic flood of May 1995. It is designed to divert flood water from the New Orleans vicinity and discharge water into the Mississippi River, at a rate of 1,200 cu-ft of flood water per second.
Our company completed the various 84" special steel pipe fittings & supports that connect to three large 84" discharge pumps. The three steel pipe lines are unique, running parallel together, off each pump and consists of eighteen 84" mitered elbows that run aboveground & underground thru the Drain & Coupling Vault, which leads toward the flood levee.
The steel pipe design is complimented by fourteen rigid supports that are welded in cross sections of 1" to 1 3/4" thick plate around the entire circumference of the 84" pipe.
It also has twelve sets of welded harness restraint ring systems, for the flex couplings, that allow angular deflection in different levels of each pipe line.
To assist in a faster installation & handling aspects, two 1 1/8" thick lift lugs were welded on each fitting. Many of these fittings had to have special freight permits & state to state highway routing, because of the over width & height restrictions.
The 630 feet of 84" pipe fittings are lined with 1/2" thick cement. The coating for the buried pipe has 35 mils of polyurethane and the exposed portion of pipe is coated with zinc primer, in preparation of a final field coating system.
Our scope consisted of strict guidelines for all phases & NDT testing of this welded pipe, too numerous to mention, for this US Army Corps of Engineers project.
Baker Pump Station No. 3
This pump station project presented multidimensional challenges. The pump station is designed for a total peak flow rate of 760,000 gpm, with pipe size varying from 84" to 102".
In addition to this tremendous flow rate, the pump station required the piping system be able to withstand the shattering impact of up to 3" diameter debris in the flow.
High yield steel with 63,900 psi yield was selected with stringent quality control for fabrication and lining/coating.
In addition, the hydraulic design dictated very tight tolerances for the entire system.
The 84" stack standing 60 ft tall above ground level, and with possibly 30 ft of water column, presented a major design challenge for wind load on the pipe and shear stress at the support. The four stacks were cross braced to provide additional stability.
This project is not only an enhancement to the City's infrastructure but also a landmark to the City's Skyline.
St. Louis Lemay Pump Station No. 1, Steel Pipe Connections
Metropolitan St. Louis Sewer District
St. Louis, MO
Pipe Construction Standard AWWA C200
170.2 lf of 96”; 97.9 lf of 48”
96 and 48
½” x 96” and ¼” x 48”
To connect a new 96" concrete force main to the pumping station, we supplied about 170 feet of 96"-diameter steel pipe; we also supplied about 100 feet of 48"-diameter steel pipe to connect the pumping station to existing steel pipe in the plant.
Between the pumping station and the existing plant piping, the team had to navigate through a web of existing lines, along with tight quarters between an existing building and a river, which resulted in the use of numerous fittings that added up to nearly as much steel as the straight sections. Among those fittings is a unique, massive 96" x 48" “reducer branch wye” that splits the 96" line into two 48" sections. Unlike typical reducers, this fitting is eccentric, with a flat side that allows the 96" and 48" reducer ends and the tangent 48" wye branch to all remain at the same top-of-pipe elevation. The 48" branches on the wye were connected to existing 48" steel lines in the plant.
This special single fitting was originally designed by the consulting engineer to be two separate fittings, a 96" x 48" eccentric branch wye, followed by a 96" x 48" eccentric reducer. Due to limited space, we redesigned the two fittings into one single fitting, unlike anything the plant had ever produced. Due to the restrictive space constraints, planning and extensive field measurements and engineering were critical. Our engineers also used 3D CAD modeling to design the 96" x 48" reducer, along with several other fittings.
The planning paid off, as the lines and connections were aligned and installed on time and without incident, with project completion in November 2014.
Southern Delivery System – Raw Water Pump Stations
Colorado Springs Utilities
Colorado Springs, Pueblo, and Fountain, CO
24 to 78
0.25 to 1.0
Over 1600 tons of steel was used to fabricate over 8000 lineal feet of suction and discharge pipe, ranging from 24" to 78" in diameter. The discharge lines tested at 510 psi, which resulted in specially designed reinforcement, including repads and crotch plates. Virtually every line required some type of fabrication including mitered elbows, tees, laterals, saddles, vortex vanes, harnesses and supports.
Eighteen 54" diameter pump cans were furnished with 69" square flanges that were precision machined to provide a perfectly level surface for the pumps.
One hundred fifteen sleeve couplings and dismantling joints were provided, requiring AWWA M11 ring harness systems for restraint.
All polyurethane coating for buried service and cement mortar lining was done at our facility.
Product / project title:
Grand Prairie Area Demonstration Project, Discharge Pipes from Station 22+00 to Station 59+00
US Army Corps of Engineers, Memphis, TN, District
DeValls Bluff, AR
The name of this project is the Grand Prairie Area Demonstration Project (GPADP). This project phase was from station 22+00 to station 59+00 and is the second phase of the overall project. This phase consisted of approximately 7,400 feet of 120" steel pipe running parallel to each other. The pipe was coated with AWWA C214 tape on the OD, and with AWWA C210 coal tar epoxy on the ID. The pipe was provided in lengths of 52.5 feet and all joints were lap welded in the field.
The GPADP is a $400 million management plan project in Lonoke, Prairie, and Monroe Counties in the state of Arkansas. The GPADP will provide water for agriculture and will also preserve the wetlands that attract millions of waterfowl each year. The GPADP will utilize water from the White River, in addition to excess surface water, to supplement a network of on-farm water recovery systems.
The GPADP consists of two phases of pipeline totaling approximately 15,000 feet of 120" pipe installed parallel to each other. These parallel lines will run between the reservoir and the Grand Prairie Pumping Station. The pump station is currently under construction in DeValls Bluff, AR. The pumping station, when completed, will pull water from the White River and transport it approximately two miles to a 100-acre reservoir. Water from the reservoir will then be distributed to local farms by a series of canals.
28th Street Stormwater Pump Station
City of Council Bluffs
Council Bluffs, IA
The project included 2100 feet of 37" pipe that consisted of (4) separate lines that ran parallel with each other. The pipe had 37" diameter with a wall thickness of .75". The pipe had a polyamide epoxy-coal tar coating and a modified polyamine epoxy lining.
Bay Division Pipeline 3 and 4 Hayward Fault Crossing Seismic Upgrade
San Francisco Public Utilities District
78 – 96
Due to the underlying geology, the various parts of the fault zone transmit forces differently. The heavy wall was designed to resist distortion and using minimum 60 ksi yield strength steel for all the sections in the specific fault zone. Under normal conditions, the creep in the fault zone will compress the pipe over time, and in the section under Interstate Hwy. 680, a large vault contains a 78" pressure balanced expansion joint, two 78" ball joints and a conventional 78" expansion joint.
The pipe also had to roll and slide in the tunnels underneath the interstate highway. All pipe sections within the fault zone were butt welded to transmit the forces along the axis of the pipe. This required extremely close tolerances on the fabricated sections in order to maintain the exact alignment. In addition, the right of way was extremely narrow and crowded, requiring a precise delivery schedule with the correct end positions, as the pipe could not be turned around. There were also many emergency bypass connections to feed or draw water from the local utility systems that required close coordination with additional agencies.
All pipe was urethane lined and coated with a cement mortar overcoat. Pipe section lengths varied from 20 ft. to 50 ft.
South Secondary Par 1085 WWTP Milestone #1
84, 72, 66, 60, 54, 48, 42, 36
0.5, 0.375, 0.25
Groundwater Reduction Plan Reaches T1, T2, and W2A
San Jacinto River Authority
42 to 60
The San Jacinto River Authority in Conroe, TX, has implemented the Groundwater Reduction Plan (GRP) which is a county-wide program that will meet the requirements of the Lone Star Groundwater Conservation District to substantially reduce future groundwater usage from the Gulf Coast Aquifer by ensuring a reliable, long-term diversified portfolio of alternative water supply sources for all of Montgomery County. The GRP will utilize a number of alternative water strategies, including conservation, reuse of treated wastewater effluent, groundwater from all Gulf Coast Aquifers including the Catahoula Aquifer, and surface water from Lake Conroe.
Phase 1 of the GRP strategy includes the design, construction, operation, maintenance, and administration of a water treatment plant and transmission lines that will treat raw surface water from Lake Conroe to meet or exceed drinking water standards, and then deliver treated water to cities and utilities within Montgomery County in the most cost-effective manner.
Reaches T1, T2, and W2A included over 10.5 miles of 42” to 60” welded steel pipe (WSP) with cement mortar lining and coating. Joints on the WSP were rolled grooved gasketed joints, with lap welded joints in restrained areas and in casings. These reaches included almost 4,500 feet of pipe in casings. To accommodate putting the pipe in casings, additional cement mortar was added in two areas on each pipe to act as casing spacers.
Affiliate New Product: A new product, service, or supply brought to the steel fabrication industry market.
Shop fabricated members have advocated extreme caution during presentations related to significant fires at their facilities. These fires caused considerable fabrication disruptions and loss of property. At least one resulted in loss of life. These fires were caused by, or accelerated by, “resin”: vinyl ester coatings.
The high levels of chemical resistance and protection provided by vinyl ester coatings is well known but comes with a significant drawback: styrene. Styrene is a highly volatile and flammable solvent that causes acute respiratory health reactions. Styrene, used to “catalyze” vinyl ester coatings, is also known as a reactive diluent. It “thins” and “cross links” this coating … but causes them to stink (as styrene quickly evaporates) and shrink (apply 10 wet mils, get only 6 to 7 dry mils).
Our company has introduced the first styrene-free vinyl ester tank coating and lining system: Magnalux 404 and Magnaplate Styrene-Free. They have all of the chemical resistance and protection provided by vinyl ester coatings without any of the hazards and limitations of styrene. They do not stink (no styrene) and do not shrink (apply 10 wet mils, get 10 dry mils). Both of these “game changing” coatings represents significant safety and economic benefits to users in shop and field-applied applications.
STI Shop & Field Fabricated members now have the opportunity to avoid life threatening association with styrene-containing vinyl ester coatings without compromising the long-term chemical resistance their customers demand. Without styrene, vinyl ester coatings can be more safely and economically applied.
Tallest Flagpole in North America
In 2014 when Acuity Insurance replaced a flagpole originally erected as a statement of resolve in response to the terrorist attacks of September 11, 2001, they aimed high…. very high. This pole, the fourth one since the original, reached an astounding height of 400 feet, achieving the distinction of being the tallest flagpole in North America. It is 100 feet taller than the Statue of Liberty – which is fitting as it reinforces America’s commitment to liberty. Our company was proud to supply custom large diameter steel flanges for this unique symbol of American freedom.
Fabricated from steel, this flagpole is built to withstand northern winters and low temperatures of – 42 degrees F and significant wind. The flagpole was designed and constructed for heavy duty service requirements similar to those required in utility scale wind towers. The general contractor, the tower fabricator and our company, all have extensive experience in providing high strength steel products for wind towers.
Our company supplied flanges that connected each section of the flagpole. The set of 12 flanges ranged in diameter from 5.5 feet to over 12 feet and the total weight of the flange set was 31,631 pounds.
Flanges were produced from ASTM A707 which is 52,000 yield strength steel designed for use in low temperature environments. The largest flange, at 12.3 ft diameter and 6 inch thickness, included 144 drilled bolt holes.
This major steel fabrication project was designed to hold a flag that is 60 feet tall and 120 feet wide which weighs 350 lbs.
This flag and flagpole is a daily reminder of America’s commitment to freedom. Additionally, at the base of the flagpole are bricks inscribed with the names of Sheboygan County residents killed in active duty.
We were honored to have participated in this unique project.
More photos and videos of the project are available at:
The 918AC is much more than an alarm, it’s a System Interface. The System Interface is capable of monitoring one (1) to four (4) simple input switch devices such as high or low level sensors, interstitial sensors, or clock gauges. Choose to have an audible alarm, visual alarm, or both when an input switch is activated. Each input is capable of having up to four (4) outputs per channel. When a sensor is activated, the System Interface is capable of opening or closing valves, activating remote alarms or strobes, and even communicating with a building security system.
Why do tank owners like it?
- AC-powered units are sometimes preferred over batteries.
- It is field-expandable up to four (4) inputs, so updating is easy when a tank is added to a site.
- Input devices are clearly labeled with a variety of pre-printed labels included with the system.
- The control center is designed to monitor one (1) to four (4) simple switch devices and provide both audible and visual indication when an input switch is activated. In addition, the 918AC has the optional capability to add 1 to 4 configurable relay outputs to interface with remote audible and visual indicators or other external simple switch devices.
- The enclosure is hinged and lockable.
Why do installers and technicians like it?
- There are three (3) pre-machined openings in the bottom of the enclosure (1-Input Connection; 1-Facility Power; 1-Output Connection)
- The connectors are modular for easy-access wiring.
- Enclosure is durable NEMA 4X for outdoor durability (non-hazardous location only).
- Easy-access installation tabs allow the box to be securely anchored.
- The unit is powered by 90-240 volt, 50/50 Hz.
- The unit contains a UL/cUL 913 Listing for Ordinary Location with Hazardous Location Intrinsically Safe Input Circuits for Class 1, Div 1, Group D.
Why do distributors like it?
- Input and output models can be purchased separately, making it easy to convert a base model to any one of the 17 different models available. Distributors can stock them!
- The enclosure is one standard size for all configurations.
- Both input and output modules are easily configured to normally open or normally closed.
- Operating temperature ranges from -40 F to 140 F. We were honored to have participated in this unique project.
A field-erected closed container, designed to ASME standards, to hold gases or liquids at a pressure substantially different from the atmospheric pressure.
Utica Hopedale Fractionator Facility
MarkWest Ohio Fractionation Co LLC
ASME Section VIII
.902 to 1.781”
These (6) large Spheres were designed and built to the strict requirements of the ASME, Section VIII, Division 2 Standard to hold 120,261 BBLS of Propane and 75,237 BBLS of Butane under extreme pressure.
The three Propane Spheres each hold 40,087 BBLS of Propane at 250 psig in a 76'-0 Sphere. The Sphere has an unusually high design pressure that requires that all welds be 100% Ultrasonic Tested(UT) for quality. Also due to the high pressure, the plates were designed to be very thick (the thickest plate was 1.781") and required that the Spheres be field Post Weld Heat Treated (PWHT) by holding the entire sphere at 1,175 degrees F for 2 hours. Before being placed into service, the Propane Spheres were then successfully hydro tested under pressure to 358 psig.
The three Butane Spheres each hold 25,079 BBLS of Butane at 100 psig in a 65'-0 Sphere. These Spheres also requires that all welds be 100% Ultrasonic Tested(UT) for quality. Prior to being placed into service, the Butane Spheres were successfully hydro tested under pressure to 143 psig.
The Scope of Work for all of the spheres included the design and construction of the foundations, as well as the design and installation of the support columns including their fire proofing, multi ring deluge fire protection spray system, a galvanized stairway and field paint of the finished product.
These Spheres used 6,633,000 pounds of steel plate and demonstrate the capability and flexibility of steel to store products at very high pressures making steel - the material of choice!
NCRA New Coker Unit
The overall execution of this project involved approximately 230,000 man-hours with a 0.00 LTIR, 4, 100 feet of welding per vessel and was constructed next to the permanent structure which was being built at the same time in order to expedite the schedule (later lifted into place by the customer).
It was a combination shop fabrication and field erection effort in order to take advantage of a controlled shop environment. We had to develop a detailed plan to construct, PWHT and hydro-test the vessels on temporary foundations on-site. We were also held to a NCRA clear weld requirement which was beyond typical code requirements. This involved highly trained welders that were capable of welding with ENiCRMo-3 in extreme weather conditions.
These vessels were designed with our Vertical Plate Technology (VPT) in order to extend the overall life and reduce future repairs to the vessels. VPT reduces the number of girth seams, eliminates shell can width and the need for plate arrangement by yield strength.
In summary, we were able to meet or exceed the customer's safety expectations, enhanced welding criteria and their aggressive schedule.
Large, welded, field-erected, low-pressure carbon or stainless steel aboveground storage tanks (including flat-bottom tanks) with a single vertical axis of revolution.
30,000 Ton Ammonia Domed Roof Tank
.1345 to 1.227
This Ammonia Tank was designed to store liquid ammonia at a bone chilling -28 degrees for an Ammonia plant.
The 135’ diameter single containment tank was designed, fabricated and erected per API 620 Appendix R. The tank weighs approximately 980 tons empty and with 17.5 million gallons of product inside, it weighs in at nearly 30,980 Tons or almost 62 million pounds.
A heating system is typically installed to prevent the soil under the foundation from freezing, and guards against damage to the slab from the extreme cold. This tank was built on a raised pile cap foundation that eliminated the need for a foundation heating system. Foam glass insulation was installed between the concrete pile cap and the tank's steel bottom to protect the concrete cap from the very cold operating temperature of the tank itself.
The specially designed dome roof was constructed on the ground inside the tank and air raised it into place along with the suspended insulated deck that hangs from the inside of the dome roof. This made erection safer and more economical. Once the dome roof was in place, the tank’s exterior was painted.
To minimize the heat leak and product boil off, an extensive insulation system was designed and installed to maintain the very cold -28 degrees F. The insulation system included Horizontal Foam In Place (HFIP) with an aluminum vapor barrier that was sprayed onto the shell and a Foam In Place (FIP) insulation that was sprayed onto the roof. The spray foam insulation is integrally bonded to both the tank shell and the aluminum vapor barrier making it very resistant to severe weather.
The single containment tank system includes a vapor recovery system and an earthen dike around the tank foundation to ensure that all potential vapor emissions and liquid leakage will be fully contained.
To obtain access to the top of the roof and the roof nozzles, a 5' diameter stair tower, access platform and roof stairway were added.
The result is a Gigantic tank, capable of holding over 17 million gallons of anhydrous ammonia, that will safely serve the customer’s fertilizer plant showing once again, that welded steel is the material of choice.
LPG Tanks / Propane and Butane
Corpus Christi, TX
59’ -0” and 68’ -0”
117’ -0” and 150’ -0”
3/16 - 1”
A terminal in Corpus Christi, TX that stores propane and butane products needed to develop 1,000,000 barrels of LPG storage capacity. EF90 chose a single source solution tank contractor to construct six (6) API-620 LPG storage tanks with dome roofs.
Adhering to the scope of work, the contractor engineered, procured, fabricated, and constructed six (6) tanks with single wall suspended decks. Additionally the scope included tank insulation, painting, and quality testing.
Quantity - Capacity - Dimensions - Product
4 each - 200,000 bbls - 150’ dia. x 68’ high - refrigerated propane
2 each - 100,000 bbls - 117’ dia. x 59’ high - refrigerated butane
Air Raised Dome Roofs
The contractor developed a thorough procedure to build dome roofs near the bottom of the tank and then air raise them into final position at the top of the tank. These 200+ ton roofs were built in pieces and utilized sub-assemblies on temporary structures in the low position as a suspended insulation deck was constructed. While in that position, a cable leveling system was installed to assist roof stabilization as it traveled from the bottom of the tank to its final top position. A seal was installed along the periphery of the lower edge of the roof which sealed the roof to the shell. Extensive shell plumb and roundness checks were made to insure a smooth ascent.
Once the roof was in position to begin the ascent to the top of the tank and all of the checklists verified, the contractor installed temporary fans. The roof was raised with a small air pressure of 0.13 psig measured with a monometer. When the roof reached the top position, crews temporarily attached the roof to the top of the tank and then welded the final connection. The entire air raise took between 15 and 120 minutes.
Personnel safety was always paramount during this procedure the same as it was in all aspects of the project. By constructing the roofs at a low elevation, the contractor limited workers’ exposure to dangerous heights, and no injuries were incurred during this project which was completed in 2014 on time and within budget.
Vertical, cylindrical, aboveground, welded carbon or stainless steel storage tanks in various sizes and capacities for internal pressures approximating atmospheric pressure. Entire tank bottom is uniformly supported.
Westway Terminals Philadelphia - 11 Tanks
69’ -2” and 71’ -2”
37’ -6” and 51’ -6”
528,700 and 997,200
.5000 - .2500”
In order to respond to the needs of the market, a New Orleans-based bulk liquid storage terminal company planned a major expansion at its Philadelphia, PA, terminal. The terminal company operates 15 bulk liquid storage terminals in the United States that can accommodate everything from food-grade products to specialty chemicals. The company brings value to its customer by developing customized storage solutions, including services such as blending, filtering, steaming and koshering. The terminal company planned to add 10 million gallons of capacity at the Philadelphia terminal by constructing 11 new tanks, including carbon tanks, stainless tanks, and different capacities, and the company needed to get the tanks in service ASAP.
The company’s tank contractor faced three significant challenges – the aggressive schedule was challenging, as was the physical space available for the project. Working in tight spaces with ongoing terminal operations all around the construction site made a clever construction plan a must. The weather was another major challenge - the tank builder began work in December, in Philadelphia. December of 2013 and the winter of 2014 in the Northeast challenged any and all construction projects, and this one was no exception.
In all, 11 new API 650 tanks were constructed on the site in a period of 11 months. The tank contractor provided the tank designs, based on the terminal company’s requirements – dictated by their customers’ storage needs. Nine tanks were carbon steel and two were stainless steel. All of the tank materials (steel plate for the tank shells, bottoms and roofs, as well as ladders, platforms, handrails and stairs) were fabricated in the tank builder’s fabrication shop. Custom design and fabrication capabilities made it possible for the tank contractor to engineer each tank’s design and appurtenances as needed for its end use.
To meet the aggressive schedule, the tank contractor developed a construction plan that included periods of time with three crews working simultaneously on three tanks. During the peak of construction there was a total of 27 men onsite building the tanks. In addition, the tank contractor expedited construction in some cases by working extended shifts in order to stay on schedule.
The tight site conditions presented challenges throughout the project. Initially, the tank contractor used the foundations of unbuilt tanks as valuable real estate for materials and constructing tank roofs. However, as tanks were completed, space became more and more scarce. Toward the end of the project, the tank builder worked creatively and safely to bring materials and equipment over perimeter containment walls and used the limited space in between the newly built tanks to complete the project.
Oiltanking Phase II – Appelt Road Project
(11) Floating Roof Tanks, Various Sizes (See description below)
This project included (11) miscellaneous Internal Floating Roof Tanks with Geodesic Dome Fixed Roofs. The tank sizes were six (6) 216' Dia x 60' H, one (1) 195' Dia x 60' H, two (2) 158' Dia x 60' H, one (1) 123' Dia x 60' H, and one (1) 112' Dia x 60' H. The customer had an aggressive schedule that we were able to accommodate, given the fact that we were in the process of completing Phase I at the time of Phase II being awarded. We were able to integrate the Phase II scope of work into our current project execution plan for Phase I. This meant utilizing some of our previously mobilized on-site resources to complete these tanks, along with additional manpower that was coming off of other projects during that time period. It allowed us to reduce the schedule by approximately 3 months from our original proposal, or about a 20% reduction in the overall schedule. The customer saw the value in overlapping these two projects and we were able to meet their need dates and complete these 11 tanks inside a twelve month time-frame.
Part of meeting the schedule dates, meant we had to work closely with our dome subcontractor to coordinate their installation. We worked out several different methods in order to provide for the most expedient erection. Those methods included erecting the dome on the tank bottom, on the installed floating roof and outside the tank which was later lifted onto the finished tank. This allowed the schedule to be flexible, allowing us to meet the commercial completion dates.
Overall, the customer was pleased with our safety, quality and performance in Phase II and awarded us Phase Ill. Phase Ill includes an additional 10 tanks and is now under construction. The final overall project will include a total of 31 tanks. Our creativeness and willingness to offer solutions to meet the customer's needs made not only this phase of the work, but the overall project a successful one for us.
50,000 Ton Double Containment Cone Roof UAN API 650 Tank
.3125 to 1.253”
This tank was designed to store Urea Ammonium Nitrate (UAN) that is a heavy, corrosive, clear liquid with an ammonia odor that is used as fertilizer. The tank was designed, fabricated, erected and painted for a fertilizer plant and was put into service in October of 2014.
Due to the product it stored, the tank was designed as a double containment tank designed to the strict API-650 Standard. The tank consists of an inner tank with a storage capacity of 227,426 BBLS at 200 F. The outer tank acts as double containment vessel designed to contain 110% of the inner tank's contents. The annular space between the inner and outer tank is protected by a rain shield which is an extension of the inner tank's cone roof to the top of the outer tank shell. The dimensions are as follows; OT 174' dia x 57' high, IT 166' dia x 65' high.
This tank was built using a patented scaffold-less tank erection method that utilizes aerial work platforms to gain access to the tank throughout the duration of its erection.
To meet the customer's needs, a welded steel tank with the proper coatings was selected as the material of choice to store this very corrosive product.
Refined Products / Puma Terminal
Puma Energy Caribbean
120’ -0” and 150” -0”
3/16 – 7/8”
The Bayamon Terminal located in Bayamon, Puerto Rico needed to expand its terminal storage capacity by 870,000 barrels. The additional capacity would allow the terminal to store more fuel oil/diesel, diesel/gas, and jet fuel. A pipeline would then transport the products to the Port of Guaynabo in the Bay of Puerto Nuevo located northeast of the terminal.
As a central consideration to this project, Puma had commercial commitments that became a scheduling factor in the timely completion of this project. They needed several of the tanks to be ready for product before others were completed. With these concerns in mind, Puma Energy Caribbean hired a single source solution contractor to construct seven (7) aboveground storage tanks.
The scope of work consisted of the design, engineering, procurement, fabrication, and construction of seven (7) cone roof tanks and associated mechanical equipment. Additionally, the tanks were painted both internally and externally, and a cooling and foam system was installed. Two of the tanks had internal aluminum floating roofs (IAFRs), and three of the tanks had stainless steel internal floating roofs (SSIFRs).
Quantity, Capacity, Dimensions, Product
1 each - 150,000 bbls - 150’ dia. x 60’ high - fuel oil / diesel
1 each - 120,000 bbls - 120’ dia. x 60’ high - jet fuel
2 each - 120,000 bbls - 120’ dia. x 60’ high with IAFRs - diesel / gas
3 each - 120,000 bbls - 120’ dia. x 60’ high with SSIFRs - diesel / gas
Hydrotesting on the tanks was essential in order to comply with project requirements and the sequential delivery of the tanks according to the scope of work. The volume of water needed to accomplish this was large. Because the terminal is located on an island, suitable water was scarce, and a procedure was developed to manage the transportation of it to the individual tanks.
Construction began in April 2013 using a schedule that complied with the dates set by Puma. During the entirety of the project, Puma requested several scope changes that created concerns for the completion of the project on time. Another factor that affected the schedule was the weather with the rainy season causing delays in construction. In spite of these issues, the contractor was able to make the necessary modifications to the schedule to keep it on track. The entire project was successfully completed in April of 2014 on time and on budget.
Keene Station No 2 Crude Oil Storage Tanks
900 (450 each)
0.7” at base
As the United States becomes more and more energy independent, expanding the storage capabilities for crude and oil is critically important. We have been heavily involved in the expansion of crude storage in the largest expanding market in the United States, North Dakota.
The second major project that we have completed for Tesoro Logistics in North Dakota, the Johnson's Corner, ND terminal represents 240,000 barrels of additional crude storage for the region (120,000 barrels per tank).
As bringing this project online was critical for Tesoro and the area, we had to build the foundations for the tanks in the winter of 2013 and mobilize for the field erection of the tanks themselves in January of 2014. This, of course, required working through the very difficult weather conditions in order to complete the project.
With the design and construction of two (2) ringwall foundations, cathodic protection systems for the tanks, and steel pontoon internal floating roofs for the tanks, as well as the tanks themselves, this project represented a major increase of storage capability.
In order to protect the tanks from the weather and the tank contents, the tanks received exterior coatings and 2 coats of epoxy phenolic on the interior.
Welded steel water storage tank, elevated by structural elements in order to increase pressure via gravity. Includes single-pedestal tanks, such as hydropillar fluted column tanks, pedisphere, and water spheroid tanks; composite elevated tanks; and multi-legged tanks.
Kinard Hall Water Storage Tank Replacement
University of Mississippi Campus
67’ – 0”
64’ -4” Tank
"OUT WITH THE OLD, IN WITH THE NEW"
The University of Mississippi needed to replace the existing 300,000 gallon elevated tank on the Ole Miss campus with a new 750,000 gallon tank. The existing tank was a cut down, re-erected, lattice column supported and riveted steel tank originally fabricated in the 40's, relocated to the campus in the 60's and still in service until the new tank was placed in service.
The Chancellor of the University selected the new, modern "all steel" single pedestal elevated tank to architecturally blend in with the community and campus settings. The new elevated tank is artfully decorated with the University's school colors and logos. As an "all steel" welded elevated potable water tank, it should last for decades providing years of continuous and reliable service.
The University and students are very pleased with the new and attractive addition to the campus.
Overall height / length (feet, nches):
1,250,000 Gallon Elevated Water Storage Tank
Illinois American Water
1.25 to .25”
This striking, unique and beautiful 1,250,000 gallon single pedestal spheroid supports over 10,400,000 pounds of water up over 118 feet in the air. The large load on poor soils required a complex foundation design using auger cast piles to adequately support the water load and tank.
The exterior graphics enhancing the tank includes a (6) color Pekin, ILLINOIS Logo underlined with several wavy blue lines representing the nearby Illinois River. The almost lifelike multi-colored flower and stem are inserted as the "i" in the Pekin lettering making it very eye catching. The Lettering and Logo were applied using the latest long lasting fluoropolymer paint system.
The tank also features a cathodic protection system, separate inlet and outlet riser pipes, a mixing system in the ball, controls in the base, provisions for future cellular cables and a roof handrail to support the antennas.
This Tank promotes and demonstrates: 1.) the flexibility of steel to be pressed and welded into smooth, double curved shapes and 2.) the aesthetics of a steel designed structure that the community is certainly proud of.
Fortification Street Elevated Water Tank
City of Jackson
174’ -6” H.W.L.
132’ – 0” Shaft (193’ to top of roof rail)
86’ -0” Tank
1-1/8” (1st cone ring)
This owner's branding effort is sealed across the city's new water tower and the city is proud to have this new asset online and getting glorious feedback from their supporters. At over 189 feet in the air, its American Bald Eagle logo painted on multiple sides of the 86 foot diameter welded steel tank shouts “American Pride” to all around this very tight site, which is barely 120' by 130' of workable space prior to the 48 foot diameter support shaft built within this space. Not only is the site itself restricted, there is an active daycare and playground immediately to the east that had to stay in operation during construction, two streets under active construction with an overpass adjacent to the south, another busy 3-lane street and train yard neighboring on the west and the City of Jackson's busy Midtown Center occupying the adjacent property to the direct north. In fact, these tight working constraints would not allow for any other style of tank at this capacity to be constructed on this site.
This colossal 1.5 million gallon Composite Elevated Water Storage Tank (reinforced concrete pedestal supporting a welded steel tank) all in total weighs more than 12 million pounds and promotes more than 265 tons of steel in the tank, shaft, foundation, and miscellaneous steel items like ladders, piping, and conduits. The entire 43,000 square feet of zinc-primed steel surface has two finish coats of epoxy on the interior and is finished off with Fluorourethane as the final exterior coat. One 16" diameter and one 12" diameter Stainless Steel inlet/outlet & overflow pipes take care of the vertical plumbing while the inside base of the shaft is used for the remaining valve work, controls, and storage.
The city was serious about their final look of this tank and revised multiple renditions of 3D renderings, sketches, mock-ups, layouts-over-actual-images, and other modelling to arrive at what they had us ultimately construct. The dome roof, less common and more difficult to design and build, was preferred because of the smoother architectural lines and flow with the surrounding buildings. This project went so well for the city that they were able to reduce or eliminate opposition for other tanks inside the city with similar site restrictions and unify their supporters.
Elevated Water Storage Tank
City of Vienna
127’ -6” H.W.L.
132’ – 0” (to top of roof vent)
36’ -0” Tank
9/32” (cone ring)
Community Pride is what this 200,000 gallon Multi-column Elevated Tank clearly demonstrates. This all-steel elevated tank holds more than 1.7 million pounds of public water and proudly announces to all locals and visitors alike the town pride with its uniquely colored exterior Fluorourethane paint system and giant BOBCAT logos custom-designed by the school's art teacher that are highlighted even at night by localized spotlights.
This tank, with its more than 115,000 pounds of steel in the foundation and tank, went from design to completed and holding water in a short 270 calendar days while overcoming some uncommon challenges. The tank had to be built in a location tucked very tightly in between existing ball diamond fields, at the back end of the school property, with no good access path to the tank site, and closely adjoins the neighboring property. Special construction staging and timing sequences had to be implored to not interfere with the town's sporting events, disturb the environment immediately around the tank, or damage the expensive ball fields, stands, and equipment. The end result is a new tank promoting growing pride to improve their ball games and intimidate their visiting teams.
Sports Park Elevated Water Storage Tank
City of Reedley
155’ -6” H.W.L.
120’ – 0” Shaft (171’ -0” to top of roof rail)
2-1/8” (1st cone ring)
This Reedley, California community sure is proud of their new Sports Park Complex that has been a long-time coming. It has had a considerable amount of layout and forethought put into every aspect of the sports park complex’s design, including locating and focusing this 1,500,000 gallon Fluted Column Tank in the central hub of the new sports park complex footprint layout.
This all-steel elevated tank supports close to 13 million pounds of water alone and peaks at 155.5 feet in the air. Due to its California location, higher winds, seismic forces, and air quality checks/controls added to the design/implementation challenges of this multi-purpose fluted column tank structure. It has an inside elevator for public transport between multiple insulated floors which are fully circumferential on both the inside and the outside, as well as metal exterior canopies that provide shade and protection to patrons. There are multiple rooms inside for various uses (including eating, concessions, & announcing) plus a serious amount of electrical, SCADA, telemetry, piping, and valve work cleverly concealed from the public interface, a passive mixing system inside the bowl, and an all-metal roof handrail and antennae atop of the tank. A complete Cathodic Protection system helps fight against the coastal corrosive atmosphere, three all-steel vertical pipes run from grade to the interior bowl area, a full column-diameter steel condensate ceiling is above the occupied space, multiple internal landings serving as structural stiffeners up the column, and over six doors and entrances which all increased the design complexity of this super tank structure.
Thousands of design and construction man-hours were spent to successfully deliver this astounding tank on this site. These many design and timing challenges were all overcome to produce the community’s newest and finest public center of attraction that is as massive as it is useful and has the following noteworthy points:
-nearly 105,000 sq. ft. of total painted steel surface
-over 815 cu. yds. of concrete support the super tank structure
-665 tons of steel was used in the water tank and supporting structure
-over 400 ft. of 12 in. diameter steel pipes fill, drain, and properly overflow the tank
-a beautiful painted color logo adorns the peaceful exterior
An aboveground, cylindrical water storage tank, constructed at grade with its diameter exceeding its height.
Plant F21 Water Storage Reservoir
San Gabriel Valley Water Company
3/16 to 5/16”
This 66' diameter potable water storage tank was designed, fabricated, constructed and coated in accordance with AWWA standards. The tank is welded steel construction and used approximately 95 tons of carbon steel (A36).
The project scope of work included the foundation design and construction as well as the design, fabrication, construction and coating of the storage tank. Also, a double stringer stairway was included in order to provide the Owner's field personnel with easy access to the roof. Other design and engineering aspects of the project include a special decorative architectural feature on the tank exterior. The Owner requested that a distinctive architectural feature be added to the tank in order to enhance its aesthetic appeal. This design element was fabricated from carbon steel and painted to accent the exterior tank color.
Proper selection and application of the interior and exterior tank coating systems is key to a tank's appearance, long term performance and value. A three coat NSF Standard 61 approved potable water epoxy coating was applied to the tank interior which will provide long term corrosion protection. On the exterior, a three coat zinc/epoxy/urethane coating system was applied which will also provide long term corrosion protection as well as excellent color and gloss retention. With routine inspection and maintenance, these coating systems will provide the Owner with many years of service.
Initial Expansion of the Groundwater Replenishment System - (2) 7.9 MG Equalization Tanks
Orange County Water District
Fountain Hills, CA
15,800,000 (7.9M each)
3/16 to 0.656”
Project scope included provided engineering, fabrication, erection and coating of two (2) 7.9 million gallon welded steel reservoirs. Foundation design for each tank required 449 concrete piles 60 to 65 feet deep, due to ground soil having extremely high liquefaction potential during a seismic event.
The project takes highly treated wastewater and purifies it through a three-step process that includes micro-filtration, reverse osmosis and ultraviolet light with hydrogen peroxide and then uses it to recharge the groundwater basin. It is the world’s largest advanced water purification facility of its kind prior to this expansion project, producing up to 70 million gallons of new water every day.
Each tank is 216 ft. diameter x 32 ft. shell height with a three bay roof structure. Construction of the two tanks utilized over 1,380 tons of steel. Both tanks were shop blasted and primed prior to field application of high performance 100% solids coating system on the full interior. It is estimated that the life-cycle of the tank coatings is 50 years.
Palmer Avenue Reservoir
City of Coalinga
3/16 to 0.696”
Design, fabrication, construction and coating of the 3.1 million gallon Palmer Avenue Reservoir. The new reservoir was a much need addition to the small farming and industrial community of Coalinga, California. Planning for this new reservoir project began in 2012 culminating in completion of construction in 2014.
Overlooking the city from a hilltop location northeast of the city, a region that continues to be parched by California's extended drought, this new reservoir provides much needed additional storage capacity allowing the city to take advantage of new water sources that could not be utilized without the additional storage capacity. To meet the state's stringent water quality requirements, this new reservoir includes a mixing system to maintain the quality of the water delivered to the residents.
930 Zone Recycled Water Reservoir
Inland Empire Utilities Agency
Chino Hills, CA
3/16 to 0.661”
Project scope included engineering design, fabrication, construction and protective coatings for this 5.1 million gallon AWWA D100 tank. This water storage tank benefits the residents and businesses of Chino Hills and Chino. Additionally, the tank provides recycled water as an additional source for landscape irrigation use and groundwater recharge. This project will save approximately 90 million-gallons per year of drinking water by diverting those uses to recycled water, while helping to drought proof the municipality's service area and keeping the cost of water low, providing a reliable source of alternative water. The hillside location of this project also required that 800 CY of soil to be moved to create a sound foundation for the tank pad.
Funding for this project has been provided in full or in part through an agreement with the State Water Resources Control Board and the Environmental Protection Agency.
New 6.0 MG Water Tank and Rehabilitation of 4.0 MG Water Tank
City of Calexico
3/16 to 0.655”
On April 4th, 2010, a 7.2 magnitude earthquake struck north central Mexico southeast of Mexicali,
just 35 miles from the City of Calexico, California. As a result of the earthquake, the City of Calexico's water system suffered damage to its existing 1 million, 3 million and 4 million gallon water storage tanks. The initial assessment of the impaired tanks was to repair only the damaged areas. After careful review and analysis of the extent of the damage, the City of Calexico decided to build a new 6 million gallon tank and demolish the 1 MG and 3 MG tanks.
The existing 4 MG tank performed better under the seismic conditions than the other two tanks due to more recent construction to updated codes and more substantial freeboard. As a result, steel was chosen as the material of choice for the new 6.0 MG tank. Furthermore, the city determined that this approach was the most cost effective because the replacement cost was less expensive than the repair cost. The Water Tank Repair and Upgrade Project began construction on April 29, 2013.
Project scope included design, fabrication and construction of the 6.0 MG welded steel tank as well as structural repairs to the 4.0 MG existing tank in accordance with the latest seismic requirements of ASCE 7 and AWWA D100.
Zone 4 Tank
Yuima Municipal Water District
Pauma Valley, CA
3/16 to 0.508”
1,200,000 Gallon Reservoir
Middle Chiquita Canyon Water Zone 1 Reservoirs A & B (3)
Santa Margarita Water District
San Juan Capistrano, CA
38’ -0” (Zone 1, A & B), 35’ -6” (Zone A) See description below
104’ -0” (Zone 1, A & B), 146’ -0” (Zone A) See description below
8,300,000 (Total) See description below
384 Tons (Zone 1, A & B), 343 Tons (Zone A) See description below
3/16 to 7/16” (Zone 1, A & B), 3/16 to 9/16” (Zone A)
The Santa Margarita Water District imports its domestic water supply and is committed to its customers to plan and develop water infrastructure facilities to protect and enhance local supply reliability.
In response to this commitment, SMWD constructed the Middle Chiquita Canyon Water Facilities to provide the region with additional new storage capacity for its newly developed water sources. These new storage tanks provide the additional storage necessary to continue service when other portions of the district's facilities are out of service for planned or unexpected outages.
The project scope includes design, fabrication, construction and interior and exterior coatings of (3) welded steel water reservoirs and appurtenances.
Zone 1 Reservoirs A & B (total values for each)
104'-0" dia x 38' - 0" ht
Total Capacity: 4.2 million gallons
Tonnage: 384 tons
Thickness: 3/16" to 7/16"
Zone A Reservoir
146'-0" dia x 35' - 6" ht
Total Capacity: 4.1 million gallons
Tonnage: 343 tons
Thickness: 3/16" to 9/16"
Angel's Camp Reservoir & Access Road Paving
City of Big Bear Lake Department of Water & Power
Big Bear Lake, CA
3/16 to 9/16”
Design, fabrication and erection of 1.0 million gallon welded steel reservoir situated in a secluded mountainous area of Big Bear Lake City. Because of its location, the tank was designed to withstand a roof snow load of 100 pounds per square foot.
Construction at the 7000 foot site elevation was difficult and was made more challenging by the small construction site with limited access and native trees that required protection and preservation. The tank was constructed and coated in under three months to meet the district's needs for added gravity storage for fire protection in this remote area.
A storage tank fabricated to meet a unique storage need and not covered under any other category.
Thermal Vacuum Chamber Addition
Space Systems / Loral
Palo Alto, CA
The existing vacuum chamber is a horizontal cylindrical shell 27 ft. in diameter with a 30 ft. long straight section (304 stainless steel cylinder). The existing chamber was decommissioned in the early 2000s and the straight section was cut into five pieces, three each 27 ft. diameter, one door frame and sealing surface section, and one end bell. The chamber was originally designed in accordance with Section VIII, Division I of ASME Code. The shell is stainless steel with external carbon steel stiffeners.
The RFP required us to design, fabricate and install to the existing cylinder section an additional two 27 ft. diameter, 10 ft. long sections. Each section included six 29 in. diameter port plates installed on one side of the new spool section.
All existing "O" rings and seals on the chamber were replaced with like seals of viton material.
Pressure Vessel - The east end (door) of the chamber will be used for insertion and removal of the spacecraft. The door end bell is truncated into two parts, one above and one below floor level. The lower part is welded to the cylindrical section and is part of the chamber. The door is hinged to one side of the chamber and opens by being rotated through a 90 - degree arc. The door was installed and rotated using the existing mechanisms. The door and its mechanisms are free standing from the chamber shell. We installed the hinge door and refurbished the hydraulic cylinders to make the door operable at its new location.
The main door section has a main access door 78 in. high and 36 in. wide. Both the main door and the manway door were provided with suitable latching devices to effect a proper vacuum seal.
The west endbell was re-welded in place.
All sections welded prior to installation were liquid nitrogen shock tested three times and then helium leak tested to demonstrate leak tightness.
New chamber penetrations consist of six 30 in. (nominal) diameter flanged openings for test station cabling. Aluminum blank off plates plus 100 percent spares were provided for all openings. Penetrations required for system completeness (cryogenic lines, gauges, pumps, doors, vacuum lines, etc.) were also installed.
We installed new hard points as called out on client's drawings for internal fixtures, as well as new mounting attachments at several locations for mounting of spacecraft sensor targets.
Sabine Pass Liquefaction Trains 1 & 2 Support Tanks
Cameron Parish, LA
1” at base
We supplied the field erected tanks for the transformation of Cheniere's existing liquefaction natural gas import facility to an export LNG facility. Awarded the nine (9) Process Tanks for Trains 1 & 2, completed in 2014, and Trains 3 & 4, to be completed in 2015, we are incredibly excited to be involved in the project.
One of only seven LNG Export Facilities to be approved to proceed by the federal government, this is the first LNG Export Facility to enter construction. As the first of many potential LNG Export Facilities to proceed, these tanks represent the start of a burgeoning new industry in this country.
The Sabine Pass site can readily accommodate up to four LNG trains capable of processing approximately two Bcf/d of natural gas. The nominal capacity of each liquefaction train would be approximately 4.5 million tons per annum (mtpa). The initial project would include two trains with liquefaction capacity of approximately 1 Bcf/d. A train is an individual processing unit of the plant. Each of the first two trains is capable of liquefying 500 million cubic foot per day of natural gas.
In 2014 we completed the first stage of tanks, which are described below:
(1) 110' x 70' Flat Bottom, Supported Cone Roof Tank
(1) 74' x 56' Flat Bottom, Supported Cone Roof Tank
(7) 27' x 38' Flat Bottom, Dome Roof Tanks
All tanks are carbon steel, with the exterior surfaces shop primed and field finish coated with three of the tanks (including the larger tanks) receiving epoxy novolac interior coatings.
With the process requirements of these tanks necessitating multiple sensors, mixers, and gauges, these tanks required significant amounts of shell and roof platforms. In many cases, the surface areas of these platforms exceeded the surface area of the roof.
Harry Tracy Water Treatment Plant
San Francisco Public Utilities Commission
San Bruno, CA
1/4 - 5/8”
A major water treatment plant
One of the upgrades at the Harry Tracy Water Treatment plant was the design, fabrication, field erection and coating of the new self-supporting umbrella roof tank.
The Harry Tracy Water Treatment Plant is located only 1,000 feet from the San Andreas Fault in San Mateo County, California. The plant, owned by San Francisco Public Utilities Commission, treats and delivers water to the people throughout the Northern Peninsula region on the western side of San Francisco Bay. It is also the only source providing emergency water to the San Francisco Peninsula.
In March 2011, the SFPUC initiated a major upgrade project to its facilities for increased resilience in the event of another major seismic event. The construction project includes seismic retrofits and electrical upgrades to enhance the plant's treatment capacity as well as several new and replacement structures.
Included in the new construction for the treatment facility is this 0.5 million gallon sludge treatment washwater tank. Due to the proximity to the San Andreas Fault, seismic design values for this tank were substantially higher than similar projects not in such close proximity to the seismic hazard. As a result, in order to accommodate limited freeboard allowed for the structure, a torispherical roof design was utilized to withstand the sloshing wave pressures imposed on the roof.
Scope of the project included design, fabrication, erection, and interior and exterior coatings for the tank as well as the foundation engineering to include both sliding and uplift anchorage.
An aboveground, cylindrical water storage tank, constructed at grade with its height exceeding its diameter.
Cape Girardeau Standpipe
City of Cape Girardeau
Cape Girardeau, MO
AWWA D100 Section 14
The City of Cape Girardeau’s Meadowbrook Water Tank is a 1.5 million gallon feat of tank building excellence, defying the limitations of space and the threat of microseismic activity.
The Meadowbrook tank is in the New Madrid Seismic Zone, the most active seismic zone in the US east of the Rockies. According to the U.S. Geological Survey, microseismic earthquakes (registering from below 1.0 to less than 2.0 in magnitude) occur, on average, every other day in this zone. This condition alone would make a tank construction project uniquely challenging, but the Meadowbrook tank also has a very tricky site. It is positioned on a one-acre parcel at the top of a ridge, next to an existing, in service water tank.
The City needed additional water storage, and a standpipe atop that hill was the solution. The City’s General Contractor (GC) worked closely with the tank contractor to coordinate the construction process. With little room to work and only one spot that was accessible by vehicles, the GC provided an all-terrain dozer to assist the tank contractor in moving the steel from the bottom of the hill to the construction site.
To meet the seismic requirements for the site, the original slab foundation design would yield a very large, very thick, very expensive slab. As an alternative, the tank contractor developed a specially designed ringwall foundation for the tank. This design permitted a smaller footprint (beneficial to the owner in terms of cost, and better suited to the ridge-line site). The proprietary foundation design provides the extra support the tank would need in the event of seismic activity. The tank contractor also designed and custom fabricated extra-large anchor chairs that are closer together and extend further up the tank’s shell to provide additional support.
The original plans also specified an Umbrella Roof. Because of the potential for seismic activity, the specs included six feet of freeboard to allow for sloshing. The sloshing requirement would result in six feet of empty space between the top water level and the tank roof – space that can’t be used and invites damage to the tank’s coating system.
The tank contractor proposed an alternative Knuckle Supported Umbrella Roof (KSUR) design that reduced the space required for sloshing and reduced the stress on the tank roof, eliminating the need for six feet of freeboard. In addition, the KSUR design has fewer potential corrosion spots and, with the correct coating system, can improve the life expectancy of the tank. This design also provides an aesthetically pleasing structure that showcases one of the community’s most vital resources.
The tank was designed under AWWA D 100 Section 14. This design standard permits the use of higher grade steel, but requires specific welds and additional x-rays throughout the construction process. The unique tank design, fabrication processes and construction plan met the stringent demands of the AWWA D-100 Section 14 standard, and facilitated the use of ¼” to ¾” steel for the tank. This reduced the overall cost, and the load bearing requirements for the foundation.
The tank contractor performed the engineering, fabrication, construction and field painting for tank. The steel plate was cut, rolled, blasted and primed in house. The tank builder’s field painting team applied the coatings. The tank’s interior coating system included a moisture cured organic zinc-rich primer to prevent corrosion, and a self-priming epoxy coating that provides resistance to water, water borne chemicals, and other aggressive environments. The KUR design works holistically with the paint system to maintain a clean, corrosion free environment. The exterior received a stain-resistance, low gloss acrylic polyurethane and was finished with a two-component high gloss fluorourethane coating that provides enhanced color and gloss retention, and provides long-term protection.
Miramar College Thermal Energy Storage Tank
Miramar Community College
San Diego, CA
This standpipe serves a southern California community college as a thermal energy storage tank. Designed to store water chilled overnight when electrical rates are lower, and utilize that chilled water throughout the day to supply the campus’s cooling demand throughout the day. Utilizing this demand shift, this tank is anticipated to save the school district $190,000 annually which combined with the long life span of the welded steel structure will allow for the tank to pay for itself many times over with energy savings.
Not only designed in accordance with the already stringent California Building Code but this tank’s location on a community college campus initiated even more stringent oversight in all stages from design though commissioning. This required a lengthy plan review process by The Division of the State Architect, and third party inspection of all aspects of the fabrication and construction.
Constructing this tank as the second phase of a central utility plant upgrade created additional unique challenges for this project. Due to ongoing operations essential to keeping the campus running the worksite and laydown were extremely constricted. This allowed for crane access from one site only complicating lift plans and requiring special consideration by the design engineers for shell plate orientation to eliminate boom interferences.
Even though hidden amongst the campuses utility buildings it was decided to make the standpipe a decorative addition to the campus, though the use of two (2) courses of stainless steel fins surrounding the upper portion of the tank, to replicates architectural elements of other campus facilities. This required 128 individual support clips to be precisely laid out and welded to the tank during erection to allow the support structure to be bolted into position after the tank insulation was installed.
Standpipe/.26MG Angel of the Winds Casino Reservoir
Stillaguamish Tribe of Indians
.25 - .375”
Constructed 260,000 gallon steel standpipe to replace existing concrete reservoir. Scope of work included demolition of existing concrete standpipe, site piping, excavation, site grading, backfill, concrete foundation, and constructing new steel standpipe with interior and exterior coatings. Special project requirements to coordinate temporary water main connection for minimum disruption to casino operations during low peak hours of operation.
Standpipe/1.7 MG Standpipe Water Reservoir No. 5
City of Toppenish
.25 - .80”
Project scope included foundation excavation, concrete foundation with 91 tons of rebar and 1,000 yards of concrete, backfill, yard piping and vaults, standpipe fabrication and erection, field painting including logo, electrical, telemetry/control system, and asphalt paving.