The other challenge was the very poor soil on which the water tank was installed. Cleveland says construction involved driving concrete precast piles into the ground to support the tank and associated pump station. This impacted both the cost of the project and its schedule. &#;It&#;s also a very noisy operation,&#; he says, so communication with the neighbors and sensitivity to working hours were important considerations.
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What Are Your Options?
Containment Solutions Inc. manufactures fiberglass tanks in sizes up to 60,000 gallons that can be tethered together for larger storage and buried underground. According to David Heiman, director of marketing, business for its tanks has been exploding in the last 10 years.
Heiman attributes this growth to the increased popularity of green projects, including water capture and water conservation, which are important for point collection with Leadership in Energy and Environmental Design (LEED) buildings applying for certification. Reducing the consumption of potable water for non-potable use by capturing rainwater and/or graywater for irrigation will earn points toward gold, silver, or platinum certification.
Historically, municipal water agencies were not interested in fiberglass water tanks, but Heiman says this is changing in a time with little or no funding. He says these agencies are looking for alternate water conservation methods and are encouraging customers to conserve water in tanks. New developments are installing fiberglass tanks in rural areas where there are no municipal services.
Customers prefer multiple large tanks, says Heiman. The ability to build a hybrid system for customers, such as schools and hospitals who are routinely buying fiberglass tanks creates opportunities for water conservation, particularly in summer peak demand periods. Rainwater can be captured in one tank, graywater in a second, and water condensate in a third. Heiman says the University of Binghamton in New York did just that. It recently bought four 50,000-gallon tanks with separate outlets to store rainwater in some and graywater in others.
American Structures designs, fabricates, installs, and services bolted and welded stainless steel storage tanks for the agricultural, industrial, municipal, and wastewater industries. Its water tanks are used to store potable, recycled, and stormwater, as well as water for fire protection. They are made to order, and come in all sizes.
Earl Wildenberg, president of American Structures, says, &#;People are getting really excited about stainless steel. It doesn&#;t have to be painted; it is resistant to corrosion, rust, and relatively maintenance-free; it is environmentally friendly; it blends into the landscape.&#;
Municipal water agencies don&#;t have to worry about refurbishing a stainless steel tank in five years, he adds. Water agencies are now looking at the cost of refurbishing existing tanks and comparing those numbers with the costs of a stainless steel tank.
Wildenberg says the company has installed a lot of smaller tanks, which can be designed for expansion later. The tank is unbolted at the bottom, the tank is jacked up and new panels are installed. They recently installed two 100,000-gallon tanks in North Dakota for a mining company. There are no differences in installing small or large tanks.
&#;It&#;s like building a garage,&#; he says. &#;Once you build an envelope, you can put anything in it.&#;
United Tank Systems is a distributor for Fusion Tanks, manufacturer of glass-fused steel tanks, headquartered in England. It also manufactures both epoxy-lined steel tanks and stainless steel tanks in all sizes. Joel Portmann, company president, says glass-fused bolted steel water tanks are like putting water in a glass.
Glass-fused steel tanks have advantages over other types of tanks. They can be built up to accommodate growth, they can be moved to another location for other uses, and they have near-zero life-cycle costs, compared to concrete and welded steel tanks, which must be recoated about every 10 years and be maintained to avoid biofilm growth, says Portmann.
What About the Price?
Glass-fused steel tanks are price competitive with concrete tanks, stainless steel and welded steel tanks as size increases beyond 200,000 gallons, but pricing is dependent on region and customer requirements, Portmann says. For example, in Wisconsin, a tank has to be built to handle snow on its roof, but in California, seismic regulations require a heavier tank&#;these variations all impact price. The cost of stainless steel tanks is tied to the price of the metal itself and becomes less competitive pricewise as the size increases.
&#;There have been times when stainless steel is a lot cheaper and times when it is more expensive,&#; says Portmann. Operations and maintenance is similar to that recommended for glass-fused steel tanks.
Wildenberg agrees that stainless steel is cost-competitive initially and has low operations and maintenance costs since it is resistant to corrosion and rust, making it cheaper to maintain.
Another element affecting price is the ability to assemble the tank at the factory if it is small enough and can be trucked to the site, thereby decreasing costs. The cutoff is 20,000 gallons, Portmann says. However, transportation of the tank materials outside of the region where they are manufactured also increases the total price.
Portmann says epoxy-lined steel tanks are the least expensive type, and are usually purchased by private companies for chemical and other liquid storage uses. New improved epoxies are now coming on the market. The original epoxies are holding up well on tanks, he says, although some require special coatings. It is still too soon to say how well the new epoxies will endure, he says.
Pricing can be a challenge, says Heiman, and can vary depending on the fittings and accessories customers request for the tanks. Fiberglass is easy to customize, but still economies of scale rule, he says. If changes are called for in the field during installation, they can be made there, in contrast to concrete or steel tanks.
Prices for fiberglass tanks are comparable to those for concrete tanks, and with water rates rising, paybacks are improving, Heiman says. Life-cycle costs for fiberglass tanks are much lower, since they don&#;t rust, because biofilm such as bacteria and algae can find no home in the underground environment due to their smooth inner surfaces. Heiman says biofilm needs a textured wall to grow on, as well as sunlight. Once installed correctly, fiberglass tanks will operate for decades without maintenance, he says.
Heiman contractors like fiberglass tanks because of the ease with which they are installed. Anchors can be transported on the same truck as the tanks, and smaller cranes are needed.
Good O&M Will Protect Assets
Operations and maintenance (O&M) standards for water tanks developed by the American Water Works Association (AWWA) have been established long enough that they have become the industry standard and adopted by virtually all the states and some countries abroad.
AWWA M42, Manual for Steel Water Storage Tanks is referenced several times in this story. Standards are found in D100 for welded steel, D102 for coating steel water storage tanks, C652 for disinfection of water storage facilities, and G200 for distribution systems operation and management. Standards for concrete tanks can be found in D110 and D115, and standards for fiberglass tanks are found in D120-09.
The following discussion was drawn from a white paper written by Randall L. Moore, vice president of special products and technical services at Utility Service Company, and an April Web seminar organized by AWWA featuring Moore as moderator with speakers Kirt Ervin, vice president for Water Quality at Utility Service Company, and Mark Johnson, director of metropolitan water operations at the Massachusetts Water Resources Authority.
The white paper, &#;A Sustainable Approach to Potable Water Quality Management,&#; can be found on the PAX Water Technologies website, under resources/white papers. The Web seminar, &#;Tank Inspections and Sustainable O&M Best Practices to Manage Water Quality&#; is available through AWWA&#;s education services. Additional comments were provided by Moore and Johnson in interviews.
Moore cautions that it is best to confirm you are viewing the most recent updates when you read the standards. The most recent update of AWWA&#;s reference book, Steel Water Storage Tanks: Design, Construction, Maintenance, and Repair, for example, was released in , he says.
Moore, Ervin, and Johnson stressed chemical cleaning, active mixing, and tank asset management as tools that will provide plant managers and operators the ability to comply with the myriad new regulations governing contaminants and disinfection by-products.
Inspections Are Important
In the Web seminar, Ervin recommends that all water agencies have a written inspection plan outlining frequency, procedures, and maintenance of records. A good inspection program can extend the life of an existing tank indefinitely, he says.
Types of inspections include weekly visual, plus once-per-year inspections via remotely operated vehicles if sedimentation is a problem, in which tanks can remain full and sediments can be removed. Dive inspections can be done every three years or longer. When tanks are drained for chemical washouts, every aspect of the tank, and distribution system can be inspected.
Johnson says that remotely operated vehicles (ROVs) are doing a great job now. A crawler tank can soak up sediment to produce a clean tank as a result. Once materials dredged from the tank are allowed to settle and dry out the remaining liquid can be discharged, he says.
Areas that should be inspected on a regular basis, says Ervin, include the roof and its coverings, low spots on roof plates, access hatches that may get unlatched and vents, which should be kept in good condition. Overflow pipes should have a good catch basin.
Openings through roofs or access hatches have allowed birds, squirrels, beer cans, and, yes, even eels, to get into the water. Roofs with low spots are prone to rust where water and snow can gather. Vents should be inspected at least once a year, and kept in good condition. A good vent has a fine mesh screen preventing wind-borne particles from entering the tank.
Johnson recommends taking outbound water samples from tanks weekly, and having them laboratory tested for bacteria. The monitored data and chlorine residuals, for example, can be plotted each week. He recommends using 1.0 milligram per liter (mg/l) chlorine residual as a measurement for an action threshold.
Furthermore, this schedule is a weekly opportunity to confirm access is intact, gates are locked, the fences are secure, there are no obvious tank problems, screens, vents, and hatches all secure, and there is no leakage due to rust or penetrations. Finally, Johnson cautions that tank ladders should not become cable trays for cell vendors. Renting space to cell vendors is a great source of needed income, he says, but don&#;t forget that these are water tanks, not antenna bases.
Johnson recommends AWWA&#;s G200-09, &#;Distribution systems Operations and Maintenance,&#; section 4.3.1, which provides a great inspection checklist.
Maintain Water Quality
When potable water sits in a storage tank, problems occur and the water stagnates. Johnson says to try and keep the age as low as possible. He quoted a white paper published by EPA and a Water Research Foundation study, which reviewed turnover rates and found they varied from one to three days and as much as five days. The Water Research Foundation study found that a turnover rate of 2.5 days of 40% of water in the tank became the optimum level.
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Tanks that are well mixed are sustainable, because they consume less disinfectant, minimize the formation of disinfectant by-products, and avoid the need to empty the tank should nitrification occur, which depletes disinfectant residual. With active mixing, the common operational practices of &#;deep cycling&#; storage tanks, onsite chlorine boosting, and tank/main flushing used to remedy problems due to poor mixing can be reduced or eliminated within the storage tank.
Also, an active mixing system can minimize icing in tanks located in northern climates and reduce ice damage to the tank interior coatings, thereby helping to minimize biofilm growth and corrosion by-products, ultimately improving water quality.
Three water quality management tools can be used to maintain water quality. Washouts at least every three years are recommended in AWWA&#;s M42 Manual for Steel Water Storage Tanks to remove sediments and clean the tank. But neither pressure washing nor the disinfection process will kill and remove biofilm on interior surfaces.
As biofilm builds up, an increasing amount of disinfectant is required. However, a low-pressure NSF standard 60-certified chemical washout can remove all biological growth from the empty tank, as well as the mineral staining typically associated with the biofilm.
Removing biofilm and stain, while the water tank is empty makes inspection and failure repairs in the coating much easier and more thorough. Maintaining the integrity of the coating will minimize biological regrowth by eliminating anchor sites where colonization occurs. Eliminating surface roughness will reduce biofilm growth.
An active mixing system certified by NSF Standard 61 which operates 24 hours a day seven days a week is highly recommended to eliminate thermal stratification and achieve homogenous water chemistry within the storage tank. Moore sites a study, which shows that passive mixing of the water when the tank fills will restratify both thermally and chemically within four hours after pumping water into the tank.
Have you ever looked at a jigsaw puzzle, unsure where to start? That&#;s what choosing the right commercial steel tank size for your business can feel like. You know it&#;s crucial &#; but how do you pick the perfect storage tank?
It may seem trivial, but believe me when I say that picking out the right tank size is an important strategic decision for your company.
In my years of working with businesses, I&#;ve seen firsthand how getting the wrong water storage tank size can lead to inefficiency, safety hazards, or even blow-up costs.
This might leave you wondering &#; What should be considered when choosing a size? How does one make an informed choice on a new tank?
Don&#;t worry! Let&#;s embark on this journey together and explore why size really matters. We&#;ll dive deep into why size matters in storing materials &#; and probably more than you initially thought.
Understanding Commercial Steel Tanks
Commercial stainless steel tanks serve many vital industrial purposes. From storing fuel to housing chemicals, they&#;re essential for smooth operations.
Their strength and corrosion resistance make them an optimal choice. Various applications for these heavy-duty storage solutions prove they can withstand extreme weather conditions without compromising their structural integrity.
However, picking the right size is crucial, especially for dry bulk materials. Too small, you&#;ll struggle with capacity issues; too big could lead to unnecessary expenses and safety concerns. Selecting the perfect tank requires careful consideration.
Other commercial tanks to consider are concrete storage tanks, steel bolted tanks, factory welded tanks, corrugated tanks, and finally a plain water tank.
The Significance of Tank Size in Business Operations
Selecting the right size for your commercial steel tank is more than just about fitting it into any available space.
A correctly sized tank optimizes efficiency. Too large, and you risk unnecessary expenditure on repairs and wasted capacity. But if it&#;s too small, overflows or frequent refills can disrupt operations.
Getting the perfect-sized tank balances cost-effectiveness with operational needs &#; key to achieving goals without compromise.
Factors to Consider When Choosing a Tank Size
Picking the right size for your storage requirements is no small task. It&#;s like finding the perfect fit in clothing, but with much more at stake.
You must consider your needs first. What will you store? How much space do you have? These are vital questions that can guide your decision.
The American Petroleum Institute advises on volume requirements based on usage and regulations.
The tank&#;s physical constraints matter, too. Ensure it fits into its designated spot without causing any safety issues like chemical leakage or workflow disruptions.
Steps to Determine the Right Tank Size for Your Business
First, understand your needs. Are you storing liquids or solids? High water supply volumes or low?
The type of material affects its storage size. For instance, liquids need more space than solids because they can&#;t be compressed.
Next, think about future growth. You don&#;t want a carbon steel storage with too little water stored in the long term.
Lastly, consult with professionals like us at Extreme Industrial Coatings. We have decades of experience helping businesses make informed decisions on stainless steel water tanks.
Benefits of Selecting the Right Size Commercial Steel Tank
It not only boosts your business&#;s confidence but also improves operational efficiency.
The correct-sized tank ensures optimal space usage, leading to more efficient operations and increased productivity. Imagine fitting into an oversized or undersized suit; it doesn&#;t feel right, does it? The same applies to tanks in industrial settings.
Moreover, proper sizing can lead to significant cost savings over time. By avoiding unnecessary capacity that would otherwise be unused, you reduce maintenance costs and maximize ROI on your investment like these successful businesses did.
The Role of Professional Consultation in Tank Size Selection
Choosing the right size is not a game of guesswork. Making the correct choice of size requires thorough contemplation, technical proficiency, and a comprehension of your company&#;s needs.
A well-experienced contractor like Extreme Industrial Coatings understands these intricacies. They use their knowledge from years spent working with various industries to help you avoid costly mistakes that come with incorrect sizing decisions.
Contact us to discuss your requirements of Epoxy Steel Bolted Tank. Our experienced sales team can help you identify the options that best suit your needs.
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