Large-capacity storage tanks are critical to many businesses and organizations, including manufacturing facilities, food processors, municipal water systems, wastewater treatment facilities, power plants, the oil and gas industry and fire protection systems. They are often used to store potable water for municipal water systems, chemicals for manufacturing, fire suppressants, food, drilling fluids, dry goods or fuel, and they must be watertight, easy to maintain and repair to perform well.
Traditionally, large tanks are either made of steel, welded together and finished in the field, or made of concrete and poured in place at the facility. Both types of tanks perform well, but both have some serious drawbacks. Steel tanks that are welded on site are difficult to finish properly on site, leading to an increased potential for corrosion, and the welds must be thoroughly inspected after completion to ensure the tank does not leak. Concrete tanks are very heavy, require a lot of time to cure, and need to be constantly resealed to prevent leaks.
A third option is a bolted tank, which uses laser or die-cut steel plates that are bolted into place in the field. Bolted tanks provide the strength of steel, are quick to install and easy to maintain or repair.
Bolted tanks offer several distinct advantages over concrete or field-welded steel tanks.
Unlike field welded or concrete tanks that must be sealed and coated in the field, bolted tanks use pre-finished sections. Each section is fabricated in an environmentally controlled manufacturing facility where the metal is formed and welded, and then coated with a surface coating before corrosion occurs. The bare metal is coated with a silica and zirconium liquid sealer that inhibits corrosion and promotes adhesion of the final surface coating, an electrostatically sprayed and thermally cured epoxy powder coating to ensure a durable, corrosion-free finish. The finishing process involves less contamination and waste because the metal fabrication and finishing work is done at the fabrication plant.
Welded steel and concrete tanks are completed in the field, which often involves spraying sealers that can have environmental consequences if not applied properly, and the process can easily be delayed by inclement weather such as rain or wind, which can inhibit the curing of the sealer or lead to overspray. In some municipalities, there may be restrictions on how or when sealants can be applied, which can lead to delays or high compliance costs. No on-site finishing is required, and bolted tanks are more convenient and environmentally friendly.
Because bolted tanks are disassembled for transport, they are more compact than welded tanks with large cross sections for transport, thus reducing transportation costs. Bolted tanks are also much less expensive to transport than the materials required for concrete tanks, as they are relatively light compared to concrete.
Bolted steel tanks allow more installation flexibility than steel or concrete tanks. They range in size from 2,500 gallons to over 2 million gallons and can be customized to fit the allocated installation space. For tight areas, tanks can be built taller, while in wider areas, the width can be increased. Depending on project requirements and local codes, bolted tanks can be built on sloped band foundations, concrete ring walls or full concrete slabs.
If additional capacity is required in the future, bolted tanks can also be easily expanded with minimal material and labor, unlike concrete or welded steel tanks that require significant time, material and labor to expand and existing tank or to build a secondary tank. Because a bolted tank is built with modular panels, it requires only more panels and the time and effort required to reconfigure and expand an existing tank.
Concrete and steel tanks require regular maintenance, including frequent resealing to prevent leaks or corrosion. They are also difficult to repair, requiring extensive labor and special tools to pour new concrete or cut, weld and repair steel tanks, which can result in high material and labor costs. Bolted tanks require minimal maintenance and last longer than welded steel or concrete tanks. If a gasket leaks, a panel corrodes or a fitting such as a valve or door needs to be repaired, the damaged part can be easily loosened and repaired or replaced.
Bolted tanks are a cost-effective, durable and low-maintenance alternative to welded steel and concrete tanks, and they can be used for almost any purpose, from storing water for a town or village to storing sand for a concrete plant. With so many advantages, they are an attractive alternative for any business or industry.
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