Permastore Construction Guide

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CONSTRUCTION GUIDEfor

TANKS AND SILOS

These are guidance notes that cover the mechanics of the various tasks detailed. They onlyrefer to issues directly connected with the execution of the works. Only authorisedpersons/contractors adequately supervised, correctly equipped and trained in all aspects ofthe risks involved and the equipment to be used should be employed to carry out this work.They must also be familiar with the safety data sheets of all products used.

It is the responsibility of the person/contractor undertaking these works to consider eachparticular installation, its environment and the specific risks involved.

Whilst every care has been taken to ensure the accuracy of this guide through 1 May 2010,Permastore shall have no liability for any loss or damage (direct, indirect, special orconsequential) arising out of or in connection with this guide. This guide is subject tosupplementation or change at any time without notice at Permastore's sole discretion. Thisguide does not constitute a representation or warranty of any kind in favour of the customer,and the customer's sole warranty is that which is provided in its sales contract with thedistributor. This guide does not amend or change such sales contract in any way.

Permastore Limited

Eye, Suffolk,

IP23 7HS,

England

Tel : +44 (0) 1379 870723Fax : +44 (0) 1379 870530

E-mail : [email protected]



Permastore Construction Guide

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LIST OF CONTENTS

PART SECTION TITLE PAGE

FOREWORD 3-6

One 1 General System Description 7-8One 2 Tools and Equipment 9-11

One 3 Planning 12-14

One 4 General Construction Information 15-19

One 5 Sheet Identification 20-21

One 6 Standard Sealants, Cleaners and Primers 22-23

One 7 Applications Requiring the use of Silicone Sealants 24-25

One 8 Tank Fixing Details 26-28

One 9 Structure Dimensions 29-30

Two 1 Foundation Design and Sealing Options 31-34

Two 2 Clamping and Levelling Systems 35-36

Three 1 Assembly of Tanks From the Base Up 37-39

Four 1 Assembly of Tanks Using Jacks 40-45

Four 2 Assembly of Tanks Using Jacks and Starter Ring 46-47

Four 3 Assembly of Double Skin Tank Sheets 48-50

Five 1 Annular Tanks 51-52

Five 2 Backfilled Tanks 53-56

Six 1 Roof Construction Introduction 57-58

Six 2 Trough Deck Roof Construction 59-60

Six 3 20° Stainless Steel Roof Construction 61-63

Six 4 External Tapered Beam Roof Construction 64-65

Six 5 External Parallel Beam Roof Construction 66-68

Six 6 GRP Roof Construction 69-70

Six 7 Pressure Testing of Roofs 71-72

Seven 1 Glass-Fused-to-Steel Floors 73-75

Eight 1 Cones 76-79

Nine 1 Ancillaries 80-89

Ten 1 Checklist 90-91

Ten 2 Low Voltage Testing 92-93

Eleven 1 Troubleshooting 94-97

Appendix A Pictures from Tools List in Part One Section 2 A1-A4




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FOREWORD

This Construction Guide is provided by Permastore Limited for its Distributors/Contractors.Distributors/Contractors are advised to study this guide thoroughly and ensure that their buildingcrews are properly trained to use the information provided. Distributors/Contractors are

contractually responsible to their customers for the quality construction of the as built structure.



Permastore Construction Guide Foreword

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This Construction Guide is intended as a quickreference manual for experienced crews trained by

Permastore. It is not intended as a do-it-yourselfmanual by end users, as it does not included step-by-step instructions for assembly, installation orcommissioning.

The Guide is correct at the time of going to press. Inthe event of any doubt concerning any technical point, please contact the Sales Office at Permastore.

Health and Safety Requirements

All work described in this guide must be carried outin accordance with all relevant local health and safetyregulations. In the United Kingdom the Health andSafety at Work Act 1974 applies. The requirementsfor training and instruction of work crews are covered by Section 2 of this Act. Regulation 3 of the

Management of Health and Safety at WorkRegulations 1992 requires a risk assessment to becarried out at all sites prior to commencement ofwork.

Irrespective of legal requirements, always observe thefollowing health and safety rules:-

1. The Safe Handling of Chemical Products

The chemical products (sealants, primers,cleaners, etc) needed for the construction ofPERMASTORE

® tanks and silos must be

handled only by experienced personnel, whoshould be adequately supervised by theiremployer to ensure that all work is carried out ina safe and correct manner. Always observe thefollowing points:-

a) Read the manufacturer's instructions on thecontainer or accompanying safety datasheet before starting to use the product.

b) Chemical products must never be allowedto come into contact with eyes or skin.

Always wear appropriate protectiveclothing and eye protectors. Use a barrier

cream on your hands and generally observegood industrial hygiene practices. Removesplashes with an industrial hand cleanser,never use cleaners or solvents to removesplashes from skin. Persons vary in theirsensitivity to different chemicals. Some persons react to trace chemicals fromsplashes on outer clothing; ensure thatclothing is properly laundered. In the eventof irritation, burns or other symptoms, refer

to safety data sheets and seek medicalassistance.

c) Do not swallow chemicals and do not usethem in areas where food is consumed. If

any chemicals are ingested, refer to safetydata sheets and seek medical assistanceimmediately. Make sure that chemical products are kept and used out of the reach

of children and animals.

d) Do not smoke in areas where chemical products are used, as many of them areflammable.

e) Do not inhale chemical vapours or dust.Use a suitable mask and ensure that theworkplace is adequately ventilated.Vapours from solvent-based products mayhave a cumulative effect over time; theyalso tend to build up in enclosed spaces. Inthe event of any symptoms, leave the workarea immediately and move into fresh air.If the symptoms persist refer to safety data

sheets and seek medical assistance.

f) Ensure that there are adequate facilities forwashing and cleansing the skin and that

appropriate cleansers and barrier creams areavailable.

g) Store chemicals in sealed containers in well

ventilated areas and out of the reach ofchildren. Do not transfer chemicals from

one container into another unless suchaction is called for by the process.

h) Clean up all spillages immediately.

i) Except for transport in closed packages orsealed containers, chemical products should

be handled only by authorised personnel.

j) Ensure that the correct equipment isavailable for handling the chemical

products provided.

k) If any person handling the chemical products on the site shows symptoms which

may be caused by exposure to the products,remove the person from the site, refer tosafety data sheets and seek medical advice.

2. Fire and Explosion Risk

Some of the products used on site are flammable.Vapours given off by some products, whenmixed with air, may be explosive. Therefore:-

a) Never use naked flames in the work area.

b) Do not smoke in the work area.




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c) Avoid the use of spark-producingequipment (electric switchgear, grinders,

etc) in the work area.

d) Never use water as an extinguishant. UseCO² extinguishers or dry powderextinguishers.

e) Ensure good ventilation in the work areaand keep chemical product containerssealed when not in use.

f) Store all flammable materials in accordance

with the relevant safety regulations.

3. Handling Hints

Chemical products used on site may have alimited shelf life, which is dependent on storagetemperature. Do not order these products

prematurely, to avoid deterioration. They should be stored in areas which are cool, dry, wellventilated and secure. Refer to themanufacturer's instructions or accompanyingsafety data sheet.

Sealants: Can burn if subjected to intense heator direct flames. To extinguish burning sealant,use CO²/foam or dry powder extinguisher.

Remove splashes of sealant on skin immediatelywith an industrial hand cleanser. Sealants

normally present no inhalation problems givengood ventilation. Scrape up spilled sealant ordrips from excessive application, then wash thearea affected with a strong industrial detergent inhot water.

Primers and Cleaners: Contain solvents andare flammable. Use them only in well ventilatedareas.

Do not smoke when using them and keep awayfrom all naked flames, intense heat or sparkingequipment. To extinguish a fire use CO²/foam or

dry powder extinguisher or, in an emergency,dry sand or earth.

Remove splashes on the skin with an industrialhand cleanser. Dry the skin with disposable

paper towels, not with a cloth towel.

Solvent vapours, even under conditions of lowrates of evaporation, can quickly build up in

enclosed areas lacking adequate ventilation.Wear a suitable air mask. If you feel drowsy,nauseous or if you experience breathing

difficulties, move into fresh air.

Never dispose of surplus sealants or cleaners intothe drains; ensure their safe removal in

accordance with regulations for the safe disposalof industrial waste. If primer or cleaner arespilled, soak up the spillage with dry sand, scoopthe sand into strong polythene bags and dispose

of them in accordance with regulations for thesafe disposal of industrial waste.

4. Site Safety

All relevant site safety regulations must beobserved. In general, these would include thefollowing requirements:-

a) Wear appropriate safety clothing, includinghelmets, masks, goggles, ear protectors,coveralls, gloves and safety boots.

b) For work above ground level, use approvedsafety harness.

c) Secure all ladders at the top. In some casesit may also need to be restrained by anassistant. If a ladder is not secured and notin use, it must be laid down.

d) Scaffolding must be erected in the approvedmanner and secured during use. When notin use, scaffolding must be left secure andwith all means of access removed.

e) All hand held electric tools and equipmentshould be of 110v type.

f) All plant and electric equipment must beinspected at regular intervals and faultsmust be repaired before further use.

g) Every installation crew must be providedwith a first-aid kit as standard equipment.

h) Personnel working on sewage treatment

plants must be protected against leptospiral jaundice. Infection is usually via broken

skin or cuts, which must therefore be properly protected. All personnel must beissued with and must always carry a special

card containing details of their occupation,the name of their doctor and precautions to

be taken against leptospiral jaundice. Thiscard must be produced when a visit is madeto a doctor or hospital and those inattendance must be made aware of theholder's occupation.




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i) Special precautions, such as the provisionof forced ventilation and lifting harness,

must be taken to safeguard personnelworking within a structure which has beenclassified as a 'confined space'.

5. Site Practice

To ensure that all work is carried out to therequired standard of quality, observe thefollowing rules:-

a) Tank kits are shrink-wrapped prior to

shipment; they should not be accepted fordelivery to the site more than 4-6 weeks before commencement of installation.

b) Store kits off the ground and clear of anysurface water. Avoid storing kits in busy

areas where they may suffer damage.c) Whenever possible, transport the sheets to the

tank site on their original packing skids. Usecare when lifting sheets off the stack.

d) Keep the storage time of sealants to a

minimum, as they have a limited shelf life,especially at high ambient temperatures.

6. Safety Awareness Signage

All Safety Awareness signage provided withinthe tank construction kit must be installed at lowlevel in close proximity to entry/accessequipment (eg Access Hatch, Ladder, Staircase,Walkway etc) ensuring that those who need toenter or access the structure for inspection ormaintenance purposes are made aware of any potential dangers.

About This Guide

Where necessary, comments on three levels have been

added to the instructions:-

NOTE: Denotes information of a general or technicalnature which may be found helpful.

CAUTION: Draws attention to actions which maycause damage to equipment or materials.

WARNING: Highlights risks of accidents or injuryto personnel.

The instructions and notes are intended primarily as a

guide for the proper construction of Permastore tanksand silos. The cautions and warnings, as well as the

general safety and health rules above, are provided in

the interests of safety. Any person in control of aconstruction project or responsible for site safety in

any other capacity must comply fully with all nationaland local safety laws and regulations; any such person

not fully conversant with these requirements mustcontact his local Health and Safety Advisory Board

for assistance. While every care has been taken toensure the accuracy of this guide up to the date of publication, Permastore shall have no liability for anyloss or damage (direct, indirect, special or

consequential) arising out of or in connection withthis guide. This guide is subject to additions,deletions or changes at any time without prior noticeat the sole discretion of Permastore.

This guide does not constitute a representation ofwarranty of any kind in favour of the customer. Thecustomer's sole warranty is that which is provided inthe customer's sales contract with the distributor ofPermastore products. This guide does not amend,

change or supersede such sales contract in any way.

Registered Trade Names and Copyright

The following trade names, PERMASTORE®,

FUSION®, ISOFUSION® V700, HV ISOFUSION®,TRIFUSION

®, ECOFUSION

®, TRIFUSION

® PLUS

and Fusion Tanks & Silos are the property ofPermastore Limited.

Permastore Limited reserves all copyright in thisguide. Neither the complete guide nor any part of it

may be used without prior permission for any purposeother than the purpose for which it is issued byPermastore.




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PART ONE – Section 1

General System Description



Permastore Construction Guide General System Description

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The Permastore product is a bolted modular systemfor the construction of tanks, silos and similar steel

structures of essentially regular cylindrical form ofdiameters from 3.41m to 85.38m (11ft-280ft) andheights from 1.4m to 29.4m (5ft-96ft) dependent uponthe diameter. Capacities range from 13m

3 to over

36,000m3

(2,860gals –

7,920,000 gals).

The system comprises essentially high-grade steelsheets, silo bolts, roof beams and panels, stiffeningand fixing members, as well as a wide range ofancillaries (manholes, flanges, launders, ladders, platforms, etc). The steel sheets, which are roll-curved to the radius appropriate for any givenapplication, are punched with one or several rows ofholes, through which they are bolted together on site.

The sheets are coated on both sides by a specialGlass-Fused-to-Steel vitreous enamelling process for

which the trade names ECOFUSION ,ISOFUSION

® V700, HV ISOFUSION

®,

TRIFUSION® and TRIFUSION

® PLUS are used.

This FUSION® family of vitreous enamel provides

cost effective storage solutions in applications fromthe storage of agricultural sludges to very demandingmunicipal/industrial effluents.

The coating is sprayed and fused onto the specially prepared sheets at the Permastore plant. Sheets aretested to confirm continuity of the Glass-Fused-to-Steel vitreous enamel coating. For protection duringtransport and storage the edges are coated with an anticorrosive system.

The overlap between sheets (both horizontal andvertical) must be coated with sufficient sealant forenough to be squeezed out when the bolts aretightened to allow it to be smoothed into a fillet whichcovers the edge of the sheet and extends severalmillimetres onto the exposed side of the sheet.Similarly, bolts and holes must have sufficient sealantto protect the bore and the shank, and to squeeze outto form a seal around the bolt head and nut. A bead of

sealant must also be used to seal the nut when plasticnut covers are utilised.

The proper application of sealant is absolutelyessential for making the tank leakproof. Strictsupervision of the sealing operation can save you a lotof trouble after completion and testing, when anyleaks will have to be made good.

Another point calling for special attention is the proper expansion of vertical sheet joints. Althoughtanks are nominally straight-sided, each ring

(horizontal course of sheets) is slightly taperedinward, so that the outer face of one ring can fitagainst the inner face of the ring below it. The slighttaper is achieved by the appropriate location of the

holes. Since each hole must be slightly larger than the bolt to facilitate assembly, all bolts must be in shear

between sheets when they are tightened. Hence theimportance of ensuring the correct straight shanklength is used. See Part One: Section 7.

Where tanks are provided with Glass-Fused-to-Steelvitreous enamel floors strict supervision is called forduring construction of the floor and any further work.The floor should be temporarily protected fromdamage which may be caused by footwear andcareless handling of tools.

Following completion of construction the structureshould be swab tested to confirm the continuity of theinternal Glass-Fused-to-Steel vitreous enamel coating.See Part Ten: Section 2 of this guide. Theapplication of this test must be witnessed by thecustomers site representative following which the 'OnSite Wet Swab Testing Results Chart' (Doc Ref:02.04.02 Appendix 7) and the 'Certificate of

Completion' (Doc Ref: 02.04.02 Appendix 4) must beauthorised by the Sub-contractor and the customer'srepresentative.

All tanks, silos and similar storage and processvessels are subject to containment and environmentalstresses. Each unit is carefully designed to givereliable performance. You must therefore ensure thatthe methods of construction as detailed in this guide

are carefully followed.

In case of doubt, don't guess; ask your employer forclarification.




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Tools and Equipment



Permastore Construction Guide Tools and Equipment

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SMALL TOOLS AND EQUIPMENT FOR

ERECTION AND TESTING

The following schedule of small tools is ourrecommendation for a single construction crew:-

1. Levelling instrument accurate to within 1.5mm

(1

/16 inch) – (recommend Dumpy or laser level). – See Appendix A Picture No: 1.

2. Large tape measure capable of measuring radiusof tank.

3. Ratchet spanner.

4. 19mm (¾ inch) A/F impact sockets x 4 (heavy

duty).

5. Tapered podgers to align holes in sheet, 3mm(1/8 inch) tapered up to 14mm (9/16 inch)(recommend Britool pry bars No 219 x 4). SeeAppendix A Picture No: 2.

6. Cold chisel.

7. Spanner set (open end and ring).

8. Screwdriver set.

9. Putty knife x 8.

10. Hacksaw and blades.

11. 1m (3ft) spirit level. See Appendix A Picture No: 3.

12. Lifting hooks for carrying shell sheets. See

Appendix A Picture No: 4.

13. Sheet plate carrier.

14. Centre punch.

15. Crowbar 3ft long.

16. Hammer – ball peign.

17. Torque wrench to cover range from 14Nm(10ft-lb) to 70Nm (50ft-lb). See Appendix A

Picture No: 5.18. Plastic bucket x 6.

19. Marker pens and chalk.

20. Mole grips. See Appendix A Picture No: 6.

21. Tin snips.

22. Pliers.

23. Scissors.

24. Broom.

25. Shovels x 2.

26. Plastic floats x 2. See Appendix A Picture No:

7.

27. Bolt croppers.

28. Small tape measure – 5m (15ft).

29. Polyester slings for moving skids and liftingsheets.

30. 12.5mm (½ inch) bridge reamer. SeeAppendix A Picture No: 8.

31. 300mm (12 inch) adjustable spanner.

32. Stilsons. See Appendix A Picture No: 9.

33. 220mm (9 inch) cutting discs x 4.

34. Safety glasses. See Appendix A Picture No: 12.

35. Ear protectors. See Appendix A Picture No 10.

36. Safety helmets. See Appendix A Picture No 11.

37. Safety harness. See Appendix A Picture No 13.

38. Gloves – good supply. See Appendix A Picture No 14.

39. Wheelbarrow x 2.

40. Large special socket ½ inch drive for anchor

bolts.

41. Cleaning cloths.

42. Selection of drill bits 3mm (⅛ inch) to 13mm

(½ inch).

43. Wet sponge continuity detector – Elcometer

model 269. See Appendix A Picture No 16.

44. Aluminium mobile scaffold tower.

45. Sealant trowels x 2.

46. One set of Allen keys.

47. String line

48. Lock-up tool chest to be kept on site.

49. 2 x 10mm (⅜ inch) shackles.



Permastore Construction Guide Tools and Equipment

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ELECTRICAL EQUIPMENT (ALL 110 VOLTS)

1. Impact gun ½ inch drive – Bosch, Makita,Dewalt or similar. See Appendix A Picture No: 15

2. Extension lead – length suitable for site.

3. Power drill. See Appendix A Picture No: 17.

4. 220mm (9 inch) disc grinder.

5. Electrical hoist for lifting sheets.

6. Jig-saw – recommend Bosch variable speed (ifholes are to be cut in tank plates) with a selectionof blades to suit above, Bosch type T118B. SeeAppendix A Picture No: 18.

7. Mobile generator if mains power is not availablefor 110v electric tools. See Appendix A Picture

No: 21.

8. HILTI Hammer Drill plus drill bits to installanchor bolts.

9. Single phase 110v Transformer.

LARGE EQUIPMENT FOR SPECIFIC

APPLICATIONS

1. Concrete vibrator for rebate concrete. SeeAppendix A Pictures No: 19 & 20.

2. Small crane, or similar, for the installation of

sheets for tanks 2 rings high and above and for positioning pallets of sheets strategically aroundthe tank when construction jacks are the preferred solution.

3. Crane to lift roof beams and centre support rings.

4. Construction Jacks are recommended for theconstruction of tanks/silos with roofs and/or

2 rings high and above. (Contact Permastore forfurther advice on suitability and usage).




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PART ONE Section 3

Planning



Permastore Construction Guide Planning

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PLANNING

1. The distributor/contractor should commission a

soil load-bearing test by a qualified soil test

engineer. Copies of the certificate should be

given to:-

a) The construction team/crew leader.

b) The customer.

The original certificate should be retained in the

distributor/contractor project file.

2. When planning the site layout the customer's

future plans should be taken into account as this

could affect the positioning.

3. A site plan must be drawn, agreed and signed by

the customer to safeguard against any possible

changes being requested after the installationcommences.

4. The distributor/contractor should ensure the

availability of the tools and equipment list in

Section 2 of this guide.

5. The distributor/contractor should appoint a

suitably qualified construction team and also

ensure that all plant and materials required will

be on site when required.

6. One suitably trained person from the

construction team should be made crew leader.The crew leader should be responsible at all

times for the safe working practices of the crew

operation, as well as ensuring safe site

conditions, correct sequence of work and co-

ordination in general.

a) The crew leader should:-

i) liaise with the distributor/contractor to

ensure the arrival of plant and

materials;

ii) liaise with the customer to discuss thesite plan and safe site working with

respect to other sub-contractors and

normal site operations;

iii) set a good example to the other

members of the crew.

b) The crew leader must also be capable of

reading site plans and drawings, and be

conversant with all aspects of erection

work.

ON ARRIVAL AT SITE

1. The Crew Leader Should:-

a) Make contact with the customer and jointly

inspect the site location to ensure that there

are no obvious safety hazards (eg overhead

power cables etc) and that clear access isavailable for delivery vehicles and

construction equipment.

b) Study the site plan and soil load-bearing

certificate.

c) Ensure that the distributor/contractor has

ordered necessary materials. Remember

that materials are not always available at

short notice.

d) Mark out the site and obtain the customer's

signature on the site plan. Do not

commence operations without this signature

unless you already have a signed copy.

e) Place and fix a centre post, if installing

foundation/bases.

f) Check with the distributor/contractor about

soil disposal and who is responsible for it.

g) Supervise the digging of the foundation

footings, placement of levelling stakes and

reinforcing.

2. The Remaining Crew Members Should:-

a) Make a thorough check of the parts box and

sheet pallets against the packing list

provided and report any shortages

immediately to the crew leader. The

distributor/contractor should immediately

report any shortages so as to prevent delays

at a later stage of the construction.

b) Do sub-assembly work on ladders and

platform. 3. During Construction

Supervision checks should be made:-

a) After excavation work is complete and

before pouring concrete, should there be

any indication of the presence of organic

matter such as rotting vegetation or other

foreign objects, work should cease and

expert advice sought.

b) To check the approved drawings footings

and base dimensions, anchor bolt, structure

bolt positions and any other relevant

measurements.



Permastore Construction Guide Planning

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c) Where construction of the tank is on a

previously prepared concrete foundation by

others, the centre point and orientation

datum's must be marked by the customer or

his representative.

d) After the base ring is complete and beforepouring concrete, the base ring should

conform with the specified levels,

concentricity (fit top angle temporarily) and

be clamped securely.

e) Following or during construction the

internal Glass-Fused-to-Steel coating

should be checked in the presence of the

customer's representative to ensure

continuity. Part Ten : Section 2 of this

guide refers.

4. After Structure Completion

The structure must be inspected by the

distributor/contractor or his delegated competent

representative in accordance with the

specifications detailed herein. Refer to the

Permastore Inspection and Maintenance Manual

Document Reference P110, as well as

Part Eleven of this guide.




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General Construction Information



Permastore Construction Guide General Construction Information

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GENERAL CONSTRUCTION INFORMATION

1. Sheet surfaces must be clean and dry whensealant is being applied. See Note 2 under'Standard Sealants and Primers Part 1 Section 6.

Sealant must always be spread to cover the total

area of the overlap to ensure correct sealing.

2. CAUTION: Glass-Fused-to-Steel sheets will bend to a natural tolerance but special careshould be taken when handling.

3. CAUTION: Take care that objects are notdropped onto any Glass-Fused-to-Steel sheets.

4. Tanks are assembled using 12.5mm (½ inch) bolts within 14mm (

9/16 inch) holes. It is

important that all vertical joints are fullyexpanded during construction to preventmovement under full hydraulic load, failure to dothis can cause leaks and deformed verticalseams.

5. For tank sheets above 10mm thick, fullyexpanded vertical joints using a tank sheet

hydraulic joint expander assembly. A sheet jointexpander kit is available from Permastore.

6. When building tanks from the base up it is easierto assemble rings of sheets working clockwise.

7. CAUTION

Bolts should be tightened to a torque of 65Nm(46ft-lb) except through tapered inserts, whichshould be tightened to a torque of 32Nm(23ft-lb).

Failure to conform to this standard may causedamage to the panels.

8.




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It is essential that the correct length bolts areused in the correct place during construction.

Always check fixings charts for the bolt sizes to be used.

9. Before inserting the structure bolts, ensure

sealant has been applied into and around each bolt hole as a safeguard against leaks.

10. It is essential to fillet all sheet edges, vertical andhorizontal, both inside and outside the structure.

11. At all points where an angle overlaps a vertical joint, tapered inserts must be used.

12. All ancillary items bolted to Glass-Fused-to-Steel sheets such as angles and brackets must be

fully coated with sealant on contact surfaces to prevent leakage.

13. All levels must always be maintained at + or – 1.5mm (

1/16

inch).

Wherever possible levels should be checkedfrom within the structure.

14. The circularity on all structures must be to thefollowing standards:-

Diameter Circularity

Up to 13.7m (45ft) ± 6mm (¼ inch)

From 14.5m to 26.5m(48ft to 87ft)

± 12.5mm (½ inch)

27.3m (90ft) and

above± 25mm (1 inch)

Refer to Part One – Section 8 for structurediameters.




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17. CAUTION: If Glass-Fused-to-Steel panelsrequire cutting on site the operation must always

be carried out using a jig-saw type cutter (referto Part Eleven – Section 1).

18. CAUTION: Do not attempt to cut Permastoresheets with gas cutting equipment or use on other parts in the locality of Glass-Fused-to-Steel,where sparks may contact and adhere to the

surface.

19. CAUTION: Do not attempt to cut Permastoresheets with a mechanical grinder or use on other

parts in the locality of Glass-Fused-to-Steelwhere sparks may contact and adhere to thesurface.




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Sheet Identification



Permastore Construction Guide Sheet Identification

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SHEET IDENTIFICATION

The sheet identification system (ID holes) is visibleexternally after construction and the ID piercing provides a clear indication of sheet thickness, steelgrade and sheet taper.

MATERIAL IDENTIFICATION

Four different hole shapes indicate the grade of steel:-

MATERIAL THICKNESS IDENTIFICATION

To indicate the sheet thickness the standard horizontal bolt holes are used as datum points.

"Whole numbers" ie 2mm, 3mm, 4mm etc are positioned 40mm to the right of the datum point andthe "half numbers" ie 2.5mm, 3.5mm etc are positioned 40mm to the left of the next datum point.For examples refer to the drawing.

MATERIAL IDENTIFICATION EXAMPLES

TAPER IDENTIFICATION

In order to ensure trouble free sheet to sheet assembly,Series 1400 sheets are produced with a slight taper toaccommodate the horizontal overlap. Dependent onthe sheet thickness and tank diameter one of the

following options will be provided. The absence ofany notch would signify a straight sheet with no taper.

Notch 1 = Taper Reference 14t Notch 1 & 2 = Taper Reference 38t

Notch 1, 2 & 3 = Taper Reference 62t Notch 1, 2, 3 & 4 = Taper Reference 86t




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Standard Sealants, Cleaners and Primers



Permastore Construction Guide Sealants and Primers

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STANDARD SEALANTS, CLEANERS AND

PRIMERS

The following list of sealants and ancillary productsrepresents those most commonly used for the standardrange of applications.

Sealant Colour

The standard utilisation policy for the construction ofall dark coloured tanks, including standard blue andgreen tanks, is to use Sikaflex TS Plus Black sealant.

For all light shades of colour including white, grey

and desert tan tanks Sikaflex TS Plus Grey sealantwill be utilised.

Sikaflex TS Plus

Used for sheet joints, painted and galvanised surfacesin direct contact with Glass-Fused-to-Steel panels,

perimeter base fillet type seals and minor internalrepairs. Due to its high performance specification TS

plus is also used for more specialist applicationsrequiring chemical and temperature resistance.

Sikasil Pool

Silicone sealant used in conjunction with Sikaflex TSPlus for the internal primary seal for onerous and/orhigh temperature applications.

Sikaflex 221

Only to be used in applications where fast cure is an

essential requirement. (Remedial, maintenance etc).

Sikaswell S2

Hydrophilic base seal.

Sikalastomer 710

Perimeter bond breaker used in conjunction withSikaflex TS Plus for tanks above 33.2m diameter and11.2m in height.

Sika Primer 3N

Concrete primer for perimeter base seals.

Sika Primer 210T

Galvanised surfaces on roof top stiffener and floorfoundation angles.

Sika Cleaner 205

General cleaner for Glass-Fused-to-Steel surfaces and pre-treatment for silicone sealant overpointing.

Permastore Repair Kit Corroless EP

Minor repairs to panel surfaces and sheet edges.

NOTE 1: Sealant and Primers may vary inaccordance with the process design criteria of thestructure.

NOTE 2: It is recommended practice for Glass-Fused-to-Steel surfaces to be clean and dry prior to

the application of the sealant. Glass-Fused-to-Steel panels are wrapped after manufacture to ensure thatthey are clean and dry at the time of construction.When it is necessary to clean the surface use Sika

Cleaner 205 or alternatively, pure xylene,methylethylketone (MEK) or isopropylalcohol (IPA).Do not use any solvents or cleaners that might leave aresidue or contain turpentine, white spirits, phenols,organic acids, surfactants or silicones. If in doubtcheck with Permastore prior to use.

Always follow the manufacturer's advice on Healthand Safety and guidelines for application and curingtimes.




Doc Ref: P132 Rev 9 1/5/10 of 97


Applications Requiring the use of SiliconeSealants




Doc Ref: P132 Rev 9 1/5/10 of 97

CONSTRUCTION WITH SILICONE

SEALANTS

1. For applications where the operational

temperatures exceed 50 ₀C or the process

conditions are particularly onerous silicone

sealant is used.

2. The tank is constructed using Sikaflex TS

Plus with the external tank sheet edges over

pointed with Sikaflex TS Plus. Sheet

surfaces must be clean and dry when the

Sikaflex TS Plus construction sealant is

being applied. See note 2 under ‘Standard

Sealants and Primers Part 1 Section 6’.

3. The Sikaflex TS Plus sealant is applied over

the bolt holes as normal but controlled

around the internally exposed sheet edges to

minimise excess sealant being extruded into

the contact area of the tank.

4. Use the extruded Sikaflex TS Plus sealant

around the internal sheet edges to form a

small protective fillet.

5. It is essential to fillet all internal sheets

edges, vertical and horizontal correctly. For

the inside of the tank structure the Sikaflex

TS Plus is over pointed with silicone sealant.For the outside of the tank structure external

pointing is completed using Sikaflex TS Plus

sealant only.

6. Following a minimum period of 24 hours

check that the Sikflex TS Plus internal

sealant is touch dry.

7.

Prior to applying the internal silicone sealantas detailed above the existing Sikaflex TS

Plus sealant fillet must be cleaned with

cleaner 205.

8. Over point the internal sheet edge sealant

with silicone sealant as detailed above.

9. This method of sealant construction will also

be used for Glass-Fused-to-Steel Floors.

10. For foundation perimeter sealing the Sikflex

TS Plus fillet should also be over pointedwith silicone sealant.




Doc Ref: P132 Rev 9 1/5/10 of 97


Tank Fixing Details



Doc Ref: P132 Rev 9 1/5/10 of 97

To be used in conjunction with the Fixings Chart on Page 26 of this Guide.



Permastore Construction Guide Tank Fixing Details

oc Ref: P132 Rev 9 1/5/10 of 97



Permastore Construction Guide Structure Dimensions

Doc Ref: P132 Rev 9 1/5/10 of 97

INTERNAL DIMENSION OF STRUCTURES

Nominal Radius Nominal Radius

Model

Diameter

Reference

Sheets

Per

Ring

MetresFeet and

Inches

Model

Diameter

Reference

Sheets

Per

Ring

MetresFeet and

Inches

11 4 1.708 5' 7¼" 146 52 22.200 72' 10"14 5 2.135 7' 148 53 22.627 74' 2⅞"

17 6 2.562 8' 4⅞" 151 54 23.054 75' 7⅝"

20 7 2.988 9' 9¾" 154 55 23.481 77' ½"

22 8 3.415 11' 2½" 157 56 23.908 78' 5¼"

25 9 3.842 12' 7¼" 160 57 24.335 79' 10⅛"

28 10 4.269 14' ⅛" 162 58 24.762 81' 2⅞"

31 11 4.696 15' 4⅞" 165 59 25.189 82' 7⅝"

34 12 5.123 16' 9¾" 168 60 25.616 84' ½"

36 13 5.550 18' 2½" 171 61 26.042 85' 5¼"

39 14 5.977 19' 7⅜" 174 62 26.470 86' 10⅛"

42 15 6.404 21' ⅛" 176 63 26.896 88' 3"

45 16 6.831 22' 4⅞" 179 64 27.323 89' 7¾"48 17 7.258 23' 9¾" 182 65 27.750 91' ½"

50 18 7.685 25' 2½" 185 66 28.177 92' 5⅜"

53 19 8.112 26' 7⅜" 188 67 28.604 93' 10⅛"

56 20 8.359 28' ⅛" 190 68 29.031 95' 3"

59 21 8.965 29' 5" 193 69 29.458 96' 7¾"

62 22 9.392 30' 9¾" 196 70 29.885 98' ⅝"

64 23 9.819 32' 2⅝" 199 71 30.311 99' 5⅜"

67 24 10.246 33' 7⅜" 202 72 30.738 100' 10¼"

70 25 10.673 35' ¼" 204 73 31.166 102' 3"

73 26 11.100 36' 5" 207 74 31.593 103' 7¾"

76 27 11.527 37' 9⅞" 210 75 32.020 105' ⅝"

78 28 11.954 39' 2⅝" 213 76 32.447 106' 5⅜"

81 29 12.380 40' 7⅜" 216 77 32.873 107' 10¼"

84 30 12.808 42' ¼" 219 78 33.300 109' 3"

87 31 13.235 43' 5" 221 79 33.727 110' 7⅞"

90 32 13.662 44' 9⅞" 224 80 34.154 112' ⅝"

92 33 14.089 46' 2⅝" 227 81 34.581 113' 5½"

95 34 14.516 47' 7½" 230 82 35.008 113' 10¼"

98 35 14.942 49' ¼" 233 83 35.436 116' 3¼"

101 36 15.369 50' 5⅛" 236 84 35.863 117' 8"

104 37 15.796 51' 9⅞" 239 85 36.290 119' ¾"

106 38 16.223 53' 2¾" 242 86 36.717 120' 5⅝"

109 39 16.650 54' 7½" 245 87 37.144 121' 10½"112 40 17.077 56' ⅜" 248 88 37.571 123' 3¼"

115 41 17.504 57' 5⅛" 251 89 37.998 124' 8"

118 42 17.931 58' 10" 254 90 38.425 126' ⅞"

120 43 18.358 60' 2¾" 257 91 38.851 127' 5¾

123 44 18.785 61' 7½ 260 92 39.278 128' 10½"

126 45 19.211 63' ⅜" 262 93 39.705 130' 3¼"

129 46 19.638 64' 5⅛" 265 94 40.132 131' 8"

132 47 20.065 65' 10" 268 95 40.559 133' ⅞"

134 48 20.492 67' 2¾" 271 96 40.986 134' 5¾"

137 49 20.919 68' 7⅝" 274 97 41.413 135' 10½"

140 50 21.346 70' ⅞" 277 98 41.840 137' 3¼"

143 51 21.773 71' 5¼" 280 99 42.267 138' 8⅛"

For tank diameters larger than those charted above please contact Permastore for further advice.




Doc Ref: P132 Rev 9 1/5/10 of 97

PART TWO – Section 1

Foundation Design andSealing Options



Permastore Construction Guide Foundation Design and Sealing Options

Doc Ref: P132 Rev 9 1/5/10 of 97

FOUNDATION DESIGN AND SEALING

OPTIONS

1. Ring Beam and Infill Design

Generally considered to be the least complexdesign and favoured where the installation team

has responsibility for the base and tankconstruction.

The ring beam can be installed prior to arrival ofthe tank kit on site and the foundation bolts positioned whilst the concrete is still wet, if

required.

The base slab (infill) is generally pouredfollowing construction of the starter or base ring.

Alternatively it is poured following completionof the tank shell if the structure is being built

using construction jacks.

TANKS UP TO AND INCLUDING 8 RINGS HIGH

TANKS ABOVE 8 RINGS HIGH.

Rebate Base Design

Utilised mainly where the base design and

construction is by a third party, it facilitates a proven concept to achieve effective hydrostaticcontainment where two separate contractingagents have responsibility for a common

workface.

2. Flat Base Design

Generally as (2) overleaf, but requires a veryhigh standard of base concrete construction toachieve an acceptable level and flatness.

It is essential that these levels of workmanshipare attained to enable the tank to be successfullyconstructed and sealed.

This concept has a limited range of use and is

only recommended for experienced installationteams.

TANKS UP TO AND INCLUDING 8 RINGS HIGH

TANKS ABOVE 8 RINGS HIGH




Doc Ref: P132 Rev 9 1/5/10 of 97

LIMITED TO TANKS WITHIN THE RANGE

3.4M (11FT) – 16.2M (53FT) DIAMETER AND

1 RING - 6 RINGS HIGH

4. Agricultural Slurry Tank Base Design

Identical to Ring Beam and Infill design with theexception that case-in anchor bolts are alwayssupplied.

TANKS UP TO AND INCLUDING 6 RINGS

HIGH

BASE PERIMETER SEAL OPTIONS

1. Perimeter Fillet Seal

a) Pour concrete to the level specified on thedrawing or level with existing foundations.Ensure that the concrete completely fills the

gap between the ring beam or floor slab andthe base angle.

NOTE: It is recommended that a concretevibrator is used to ensure that the concretefully flows beneath and around the base

angle.

b) When the concrete has cured sweep cleanthe perimeter of the foundations inside the

tank to remove any surface debris.

c) Clean the Glass-Fused-to-Steel surface

immediately above the concrete level insidethe tank to ensure good adhesion for thesealant fillet. See Note 2 under 'StandardSealants and Primers' Part 1 Section 6.

d) Apply primer to the concrete base only

extending approximately 50-60mm(2 inches) inwards from the tank wall.

e) Review the instructions for use of the

perimeter sealant being used and then applythe sealant.

f) Allow to cure as manufacturer's instruction.




Doc Ref: P132 Rev 9 1/5/10 of 97

2. Perimeter Fillet Seal with Bond Breaker

for tanks above 33.2m diameter and 11.2m

in height.

a) Pour concrete to the level specified on thedrawing or level with existing foundations.Ensure that the concrete completely fills thegap between the ring beam or floor slab andthe base angle.

NOTE: It is recommended that a concretevibrator is used to ensure that the concretefully flows beneath and around the baseangle.

b) When the concrete has cured sweep clean the perimeter of the foundations inside the tank toremove any surface debris.

c) Clean the Glass-Fused-to-Steel surfaceimmediately above the concrete level insidethe tank to ensure good adhesion for thesealant fillet. See Note 2 under 'StandardSealants and Primers' Part 1 Section 6.

d) Apply primer to the concrete base onlyextending approximately 50-60mm (2 inches)inwards from the tank wall.

e) Apply the perimeter bond breaker as detailedand ensure it is touch dry and then apply the perimeter seal fillet.

f) Allow to cure as manufacturer’s instructions.




Doc Ref: P132 Rev 9 1/5/10 of 97

PART TWO – Section 2

Tank to Base Clamping andLevelling Systems



Permastore Construction Guide Clamp and Levelling Systems

Doc Ref: P132 Rev 9 1/5/10 of 97

ANCHOR BOLT AND CLAMP

1. Brush clean the top surface of the ring wall.Mark out the tank radius on the concrete surface.

2. Place shims inside each anchor bolt at the correct

radius from the centre point of the tank.

Check the levels of the shims to within 1.5mm(1/16 inch).

3. There must be a minimum gap of 25mm (1 inch)

between the foundation angles and foundationconcrete.

4. It is essential that anchor clamps are clampeddirectly onto a shim pack.

LEVELLING SYSTEM

1. Using a Dumpy level (or similar) check that allthe levelling plates are installed to within 1.5mm(1/16 inch), whilst always maintaining a minimumof 25mm (1 inch) gap between the foundationconcrete and the underside of the base angles.Tighten the levelling plates.

NOTE: Always maintain an even adjustmentof the levelling plates.

2. From the tank centre stake mark out thefoundation angle radius on to the levelling plates.Place the foundation angles round the tankcircumference, on top of the levelling plates,ensuring that when sheets are fitted, verticalseam joints are adjacent to a levelling system,with another levelling system situated mid sheetand all are equally spaced.

3. Fit the hold down clamps onto the outer anchor bolt and foundation angle and loosely tighten,

whilst checking that the correct radius ismaintained.

THROUGH ANGLE FIXING (EMBEDDED AND

FLAT BASE TANKS)

1. For Through Angle fixing the base angle will besupplied pre-punched to identify the location ofthe anchor bolts. Position of bolt holes to beused is shown on construction drawings.

2. For applications where the tank is constructedfrom the base ring upwards (stack building) the

foundation bolts are installed followingcompletion of the base ring. For applications

where the tanks are constructed using jacks thefoundation bolts are installed following

completion of the final ring of sheets (base ring).

3. It is essential that shim packs are located in close proximity to the foundation bolts and PVCisolation washers are fitted.



Permastore Construction Guide Assembly Methods

Doc Ref: P132 Rev 9 1/5 /10 of 97

ASSEMBLY OF TANKS AND SILOS FROM

THE BASE RING UPWARDS

The Base Ring of Sheets

1. Refer to bolt charts for correct bolt placement

and assembly.

2. Apply sealant to the inside face of the foundation

angles and proceed to fit the foundation sheets

ensuring that angles are fitted with an equal

overlap from each vertical joint and tapered

inserts are fitted at the vertical joint positions of

the foundation angles. See Note 2 under

'Standard Sealants and Primers' Part 1 Section 6.

3. Working in a clockwise direction around the

circumference, apply sealant to the inside face of

the vertical overlapping sheet seam ensuring all

bolt holes are covered.

4. Leaving out 2 bolts from each vertical seam (the

top bolt and the bolt positioned 5 up from thebottom), install all remaining bolts checking that

sealant has been applied over each bolt hole

before inserting the bolts.

SPECIAL NOTE: It is essential that top

angles are fitted temporarily to maintain the

tank shape. Bolt the angles to the top of the

ring of sheets, without sealant, using 6 bolts

equally spaced and tightened to

25Nm (18ft-lb).

5. Before tightening the bolts in the vertical seamensure that it is fully expanded using the 2 bolt

holes previously left for this operation (see Note

4 above).

6. For tank sheets above 10mm thick, fully expand

vertical joints using a tank sheet hydraulic joint

expander assembly. A sheet joint expander kit is

available from Permastore.

7. Fit all remaining base sheets.

SPECIAL NOTE: If the levels or the

concentricity are not maintained, problems

will occur when building higher rings,

especially the final stiffener angles.

Diameter Circularity

Up to 13.7m (45ft) ± 6mm (¼ inch)

From 14.5m to 26.5m

(48ft to 87ft) ± 12.5mm (½ inch)

27.5m (90ft) and

above ± 25mm (1 inch)

8. After the vertical joints are fully expanded top

and bottom fit the two bolts left out for this

operation and tighten to correct torque.

NOTE: Check the concentricity of the structure

at this point.

9. Tighten all bolts to 65Nm (46ft-lb) torque with

the exception of bolts through tapered inserts,

which should be tightened to 32Nm (23ft-lb)

only.

10. Remove the temporarily fitted top stiffener

angles.

11. Using a pointing trowel, fillet off the vertical

seam sealant as shown below.

12. We recommend the installation of an expanding

peripheral waterstop as shown on the project

base drawing.




Doc Ref: P132 Rev 9 1/5 /10 of 97

INTERMEDIATE RINGS


and assembly.

2. Build the second ring of sheets using suitable

lifting equipment.

3. Mark all structure holes for the wind stiffener

clip angles with chalk before assembling the ring

of sheets. As the sheets are constructed fit the

clip angles at the same time as the structure bolts

are installed.

FOUR CORNER JOINT VIEWED FROM

EXTERIOR OF TANK

SPECIAL NOTE: It is essential that top

angles are fitted temporarily to maintain the

tank shape. Bolt the angles to the top of the

ring of sheets, without sealant, using 6 bolts

equally spaced and tighten to 25Nm (18ft-lb).

4. Fully expand vertical joints and check

concentricity.

5. For tank sheets above 10mm thick, fully expand

vertical joints using a tank sheet hydraulic joint

expander assembly. A sheet joint expander kit is

available from Permastore.

6. Tighten from the centre of each sheet to either

corner on the horizontal seams; tighten the

vertical seam from the corner joint to the top

ensuring that the seam is expanded.

NOTE: If possible, do not start a new ring of

sheets late in the day if only a small number of

sheets will be completed. Where it is not

possible to complete a full ring of sheets by the

end of the day, secure each end of the unfinished

ring with ropes to prevent any possible overnightwind damage.

7. Before tightening a partially completed ring,

ensure the end sheets are truly vertical, as these

sheets tend to lean.

8. Apply sealant fillets to cover sheet edges on

vertical and horizontal joints inside and outside

the tank.

9. Remove the temporarily fitted top stiffener

angle.

10. All bolt heads are to have a sealant squeeze out

and the 4 corner joints should be completely

covered with sealant.




Doc Ref: P132 Rev 9 1 /5 /10 of 97

PART FOUR Section 1

Assembly of Tanks and SilosUsing Construction Jacks




Doc Ref: P132 Rev 9 1 /5 /10 of 97

ASSEMBLY OF TANKS AND SILOS USING

CONSTRUCTION JACKS

Important Information

a) Permastore construction jacks are designed to

build only Permastore structures.

b) The construction jacks must only be operated by

trained and competent personnel.

c) The jacks must not be used when wind speeds

exceed 25mph (40km/hr). If the wind speed

approaches this figure the structure should be

lowered and anchored down to the base. Special

care is needed when gusting winds can exceed

this figure.

d) The structure should be lowered and anchored

each evening in case of overnight winds.

NOTE: For c) & d) above, ensure that

anchors are removed prior to jacking.

e) An electrically driven 'Master Jack' drives the

jack units via PTO drive shafts.

f) Standard operation is for one jack per vertical

seam of the structure with one master jack. For

certain applications slave gearboxes are available

to reduce the requirement for standard

construction jacks (see page 45). Extra jacks

may be used and extra master drive jacks

required for special structures.

It is recommended that jacks be used on both

seams adjacent to platforms and similar heavy

ancillaries.

g) Before setting up the jacks it is essential to

ensure that they stand on a firm, level

foundation. The jack bases must be level to

prevent overloading of individual jacks and to

ensure that the structural load is evenly

distributed across all of the jacks.

h) The jacks must be positioned vertically, fixed to

the concrete base using the foundation bolts

provided or clamped to the bottom sheet/angle

and supported by centre and side stays. Centre

and side/top stays must be utilised on every

installation. Special length top stays are

provided for use with Slave Gearboxes.

i) The jack spacer plate must be used between the

carriage and structure sheet.

j) Ensure that electricity supply cables cannot be

accidentally damaged or cut, cover over ifnecessary. The use of armoured cable is

recommended.

k) Jacks are generally used to construct tanks and

silos which are 3 rings high and above. They are

also regularly used to construct structures with

roofs or starter rings. (Contact Permastore for

further advice on suitability and usage).

l) Permastore construction jacks are regularlymaintained and load tested. Copies of test

certificates are available to confirm suitably.

CONSTRUCTION JACK MAINTENANCE

Before Commencement of Work

1. With jacks vertical, check gearbox oil is up to

level plug. (Use EP90 or equivalent).

2. Check splines on gearbox and PTO shafts for

wear or damage and ensure that locking pins are

free and oiled. Grease splines on both and

ensure PTO shaft guards are fitted correctly.

3. Examine motor couplings and drive shaft splines

for wear and check motor/gearbox alignment.

4. Check all turnbuckle threads are free and oiled

and stays are in good condition.

5. Examine jack carriage assembly for damage or

wear and oil jack drive screw.

Daily Checks

1. Check jack lifting carriage assemblies fordamage and security.

2. Check jack retaining clamp for tightness.

3. Examine jack support stays and pins and check

jacks for being upright with masons level.

4. Make sure that jack lifting bolts and nuts are

always in good condition. Any replacement

bolts must be to the correct grade and shank

length. (Minimum Grade 8.8).

Weekly Checks

1. Jack gearbox oil levels.

2. Grease rollers on rear of jack carriage plate.

3. Grease PTO shaft universal joints.

4. Oil jack drive screws.

NOTE: Ensure that all jacking equipment is kept

clean and in a serviceable condition during the

construction period.

After construction is complete, fully examine all partsfor wear and lubricate before packing away.




Doc Ref: P132 Rev 9 1 /5 /10 of 97

TYPES OF CONSTRUCTION JACK

Within our stock of construction jacks that are

available for hire we have two distinctly different

models.

1. High Level Gearbox

The high-level gearbox jacks have the gearbox

and transmission shafts located at the top of the

jack body and have a swivel mounted base plate

for conical foundations. The high level jacks are

tested for a safe working load of six tonnes

(13,200 lbs).

2. Low Level Gearbox

The low-level gearbox jacks have the gearbox

and transmission shafts located at the bottom of

the jack body and the drive motor is an

independent unit which is floor mounted

between two jacks. The low-level jacks are

tested for a safe working load of four tonnes

8,800 lbs).

3. Slave Gearboxes

One advantage associated with the low-level

jacks is the opportunity to utilise 'slave

gearboxes' for a specified range of applications.

Slave gearboxes are low cost units that allow

safeconstruction utilising a reduced number of jack legs.

The advantage being more cost effective use of

the jack legs by reducing the amount required to

construct a specified vessel and facilitating

increased use of a limited number of high cost

assets.

Special length top stays are provided for use with

slave gearboxes to ensure positive location of the

assembled equipment. Centre stays and top stays

MUST be utilised on EVERY installation.

A recommended usage chart for slave gearboxes

and low-level jacks is included for reference (see

page 45).

SETTING UP FOR JACK CONSTRUCTION

1. Set up base angle, level and check concentricity.

2. Place jacks inside structure on base.

3. Assemble top row of sheets onto base angle.

Apply sealant to vertical seams only; locate onto

base angle with four bolts per sheet. Expand

sheets and tighten vertical bolts to 65Nm (46ft-

lb).

4. Re-check concentricity and clamp down base

angles.

5. Place jacks at every vertical seam as standard

layout ensuring that they are the correct distance

from the tank wall. For Low Level Jacks the

dimension from inside tank wall to the front face

of the Jack Column should be 140mm and for

High Level Jacks 56mm.




Doc Ref: P132 Rev 9 1 /5 /10 of 97

6. Use level to check jack base plates. Pack up

with shims if necessary as the jacks must be on

level base datum to prevent stress during lifting

and possible gearbox damage due to over-run.

Level carriage plates and bolt to sheet using

spacer plates. Make sure that carriage plates are

at their lowest position without fouling the jackstops.

7. Fit support struts, check that jacks are vertical

and clamp down with foundation bolts through

the base plates or use clamps.

8. Install the motor mounting assembly to the

master jack and connect the drive shaft and cover

guard.

CARRIAGE PLATE ASSEMBLY

9. Fit PTO shaft guards over the universal joint

connections.

10. Check oil levels and lubricate screw thread.

INSTALLED HIGH LEVEL JACK ASSEMBLY

OPERATION OF JACKS

1. Jack bolts must be of the correct size and

strength.

2. Ensure that the jacks are in the low position

before connecting to the sheets and a spacer is

located between the carriage and the sheet.

3. In all cases a jack bolt must be fitted to every

accessible hole in the carriage plate. A minimum

of three jack bolts must always be utilised.

4. Loosely tighten the jack bolts and raise the

structure until weight is being taken on the jacks.

Ensure that the jack bolts are located in the

bottom of the carriage plate slots and tighten to

65Nm (46ft-lb) torque.

5. Raise the top ring of sheets to the correct height

for installation of the next row of sheets or roof.

CAUTION: Isolate drive motor and remove

drive shaft before commencement of work.

WARNING: When raising the jacks they must

not be run up to the end stops. The carriage plate

must not travel beyond the safe working area.

This will result in damage to the unit and if

persistently abused this could result in failure of

the equipment.

6. Apply sealant and hang the second row of sheets

in an anti-clockwise direction. Leave out the

bolts at the position the jacks will locate on thenext lift.

7. Complete a full ring of sheets and fully expand

the vertical seams before tightening.

8. Fit wind stiffener assemblies where applicable as

full rings are completed.

9. Loosely pull in any gaps in sheet faces, tighten

from centre to both corners on the horizontal

seam and tighten the vertical seam from the

corner down to the bottom ensuring that the joint

is fully expanded.

10. When the ring of sheets is complete lower the

structure onto supports until the weight is taken

off the jacks. Remove the jack bolts and spacer

bars and lower the jacks to locate on the next

sheet. Check that the carriage plates jam whilst

lowering.

WARNING: When lowering the jacks they must

not be run up to the end stops. The carriage plate

must not travel beyond the safe working area.

This will result in damage to the unit and if

persistently abused this could result in failure of

the equipment

11. Repeat the procedure until the structure is

complete.




Doc Ref: P132 Rev 9 1 /5 /10 of 97

JACK SYSTEM USAGE CHART(For guidance only)

Series 1400 Low Level System

Each jack leg has a safe working load (SWL) of 4000 kg (8,800 lbs). For small diameter standard tanks use a jack leg on every vertical seam. For other standard structures up to and including 5 rings high use a combination

of jack legs and slave gearboxes as recommended within the usage chart. Slave gearboxes are suitable only for

structure diameters included within the chart.

For tank diameters outside the scope of this chart including tanks with roofs and any tank in excess of 6 rings high

you must refer to Permastore for advice and confirmation of jack usage.

Sheets Per Ring

(SPR)

Model Diameter

(ft)

Jack Legs

(No

of units)

Slave Gearbox

(No

of units)

6 17 6 0

7 20 7 08 22 8 0

9 25 9 0

10 28 10 0

11 31 11 0

12 34 9 3

13 36 9 4

14 39 10 4

15 42 10 5

16 45 10 6

17 48 10 718 50 10 8

19 53 10 9

20 56 11 9

21 59 11 10

22 62 12 10

23 64 12 11

24 67 13 11

25 70 13 12

26 73 14 12

27 76 14 13 28 78 15 13

29 81 15 14

30 84 16 14

31 87 16 15

32 90 17 15

33 92 17 16

34 95 18 16

35 98 18 17

36 101 19 17

37 104 19 18

Table Continued on Page 46




Doc Ref: P132 Rev 9 1 /5 /10 of 97

Table Continued from Page 45

Sheets Per Ring

(SPR)

Model Diameter

(ft)

Jack Legs

(No

of units)

Slave Gearbox

(No

of units)

38 106 20 18

39 109 20 19

40 112 21 19

41 115 21 20

42 118 22 20

43 120 22 21

44 123 23 21

45 126 23 22

46 129 24 22

47 132 24 23

48 134 25 23 49 137 25 24

50 140 26 24

51 143 26 25

52 146 27 25




Doc Ref: P132 Rev 9 1 /5 /10 of 97

PART FOUR Section 2

Assembly of Tanks and Silos UsingConstruction Jacks and a Starter Ring




Doc Ref: P132 Rev 9 1 /5 /10 of 97

SETTING UP FOR TANK/SILO

CONSTRUCTION USING JACKS AND A

STARTER RING

Standard base structures may incorporate a starter ring

located onto the base angle. Starter rings are

generally used where a tank/silo may be extended atsome future date. They are also used to progress

installation of the base foundation and can be supplied

in advance of the main tank kit.

Starter Ring

1. Locate jack support plate (Part No. 512805) at

starter ring vertical seam. Space out with

washers to allow for thickness of base sheet.

2. Set up construction jacks as standard procedure.

3. Secure jacks by drilling and rawl bolting through

jack base plate into concrete or use clamps.

4. Fit structure support brackets (Part No. 523355)

to starter ring.

5. Hang top row of sheets onto jack carriage plates

using sealant, fit all bolts, expand seams top andbottom, check circularity and tighten to torque

65Nm (46ft-lb).

6. Continue installation as described in

Part Four - Section 1.




Doc Ref: P132 Rev 9 1 /5 /10 of 97

PART FOUR Section 3

Assembly ofDouble Skin Tank Sheets




Doc Ref: P132 Rev 9 1 /5 /10 of 97

ASSEMBLY OF DOUBLE SKIN TANK SHEETS

1. A Permastore Site Supervisor is recommended

for the installation of double skin sheets, unless

the Distributor has prior supervised experience.

2. Refer to Construction Guide PART THREE

Section 1 for general tank construction guidance.


and assembly.

4. Ensure double skin sheet assembly rig is

provided and ready prior to construction.

5. Lift the inner double skin sheet onto the

assembly rig ensuring the sheet is positioned as

shown below.

6. Apply sealant to the vertical and horizontal bolt

seams and to the outer surface of the inner sheet.

7. Lift the double skin outer sheet onto the inner

sheet ensuring the holes are aligned as shown in

the view below. Bolt the inner and outer sheettogether using the 8-off bolt holes in the centre

of the sheet.

8. Lift the assembled sheets into position for the

tank shell construction and apply sealant to the

vertical and horizontal bolt seams of the outer

double skin sheet.

VIEW OF ASSEMBLED INNER AND OUTER DOUBLE SKIN SHEETS ON ASSEMBLY RIG

Outer double skin tank sheetInner double skin tank sheet

Assembly rig




Doc Ref: P132 Rev 9 1 /5 /10 of 97

9. Fully expand vertical joints using the double skin

tank sheet hydraulic joint expander assembly. A

sheet joint expander kit is available from

Permastore.

10. The vertical joint and corner assembly

arrangements for double skin and quad row

vertical series 1400 sheet joint interchanges are

shown below as viewed from the exterior of the

structure.




Doc Ref: P132 Rev 9 1 /5 /10 of 97

PART FIVE Section 1

Annular Tank Construction



Permastore Construction Guide Annular Tank Construction

Doc Ref: P132 Rev 9 1 /5 /10 of 97

ANNULAR TANKS

Annular tank systems are generally used for

continuous process applications. They provide a cost-

effective solution where floor space is at a premium.

The basic concept is two circular tanks of equal

height, one inside the other.1. When constructing an annular tank system, first

mark out on the foundation both the inner and

outer tank internal diameters. Also mark a line

from the centre which crosses the internal and

external marked diameters for each of the baffle

walls.

NOTE: Before commencing construction work

check all the relevant drawings for layout

configurations of tanks, especially if they

incorporate launders, baffle walls or revolving

bridges. It is important to ensure the correctorientation and fitment of all constituent parts.

2. Construct the inner tank in accordance with the

instructions specified in Part Three or Part Four

of this guide. Ensure the baffle wall fixing holes

are in line with the marked positions. Fit

external stiffener angles as specified on the

arrangement drawing and all exposed fixings on

the exterior of the inner tank must be protected

using the plastic nut caps provided.

3. Construct the outer tank around the inner tanktaking care to ensure that the baffle wall fixing

positions are in alignment and the datum levels

are consistent with the inner tank.

PLAN VIEW OF TYPICAL ANNULAR SYSTEM




Doc Ref: P132 Rev 9 1 /5 /10 of 97

PART FIVE Section 2

Backfilled Tank Construction



Permastore Construction Guide Backfilled Tank Construction

Doc Ref: P132 Rev 9 1 /5 /10 of 97

BACKFILLED TANKS

Backfilled tanks are designed to be constructed either

wholly or partially below ground level.

IMPORTANT NOTICE: All work must be

undertaken by competent building crews familiar

with the relevant regulations with particular

regard to Health and Safety. Furthermore, it is

the responsibility of the building crew undertaking

these works to consider each particular

installation, its environment and the specific risks

therein prior to commencement of work, to

determine the protective equipment required by

personnel and to plan the safe system of work that

should be adopted in order for the task to be

carried out safely.

1. Check all relevant drawings for layoutconfigurations. It is important to ensure the

correct orientation and fitment of all constituent

parts.

2. The tank should be constructed in accordance

with the instructions specified in Part Three or

Part Four of this guide.

3. During construction it is essential that all the

stif fener bands are positioned as shown on the

general arrangement drawing and all exposed

fixings on the exterior of the tank must beprotected using the plastic nut caps provided.

4. Before the backfill material is laid the tank must

be successfully hydrostatically tested to ensure

complete expansion and as a check on all joints.

The water level must be maintained during

backfilling to prevent possible load damage.

5. The backfill should be placed in layers 300mm

(12 inches) deep. Each layer must be fully

circumferential. Take care if excavated earth is

being re-used to backfill the tank, this may

contain larger stones or boulders which maydamage the tank. Sand or pea gravel are the

preferred backfill materials but if you are using

local earth then hardboard sheets should be used

to prevent damage.

6. If the backfill material is to be compacted the

density of the compacted material should not be

greater than the surrounding conditions. Ensure

that machinery used for compaction does not

damage the tank walls.

7. Unless the tank is specifically designed to suchloads all heavy vehicles or equipment should not

be allowed close to the tank wall. An angle

drawn at 45° from the tank wall/base level gives

the intersection. Where it is essential that heavy

traffic passes close to the tank or parks close to

the tank for process purposes, the tank should be

backfilled locally with concrete.

8. Where tanks are designed to be backfilled with afully drained material a positive drainage system

should be provided.

RECEPTION PITS

Important Notice

All work must be undertaken by competent

building crews familiar with the relevant

regulations with particular regard to Health and

Safety. Furthermore, it is the responsibility of the

building crew undertaking these works to consider

each particular installation, its environment andthe specific risks therein prior to commencement

of work, to determine the protective equipment

required by personnel and to plan the safe system

of work that should be adopted in order for the

task to be carried out safely.

1. Reception pits are available in a range of sizes

up to a maximum 20ft diameter, usually 1½ rings

deep. They are mainly utilised in agricultural

applications as gravity fed collection tanks.

2. For excavation dimensions refer to the approved

reception pit drawings (supplied separately).

EXCAVATE THE PIT AREA

1. Mark out the perimeter.

2. Determine the total depth and diameter of the pit

excavation required and proceed with the

excavation, allowing an additional 600mm

(24 inches) on the diameter. Should there be any

risk of soil collapse the excavation area may

have to be increased accordingly.

DANGER: Under no circumstances shouldanyone get into the excavation at this stage.




Doc Ref: P132 Rev 9 1 /5 /10 of 97

ASSEMBLE THE PIT

1. The pit should be assembled, above ground, on a

suitable level and firm foundation, ie on an area

of concrete adjacent to the excavated site.

2. Apply sealant to one vertical and one horizontal

seam only, ensuring the bolt holes are covered.

3. Start by bolting just the top full ring of sheets

together using the standard overlap right over

left.

4. Fit the top stiffener angles to the ring of sheets

using tapered inserts at sheet overlap points.

5. Fit anchor rods at regular spacing as shown on

the approved pit drawing.

Temporarily fit the foundation angles to the pit

without sealant. Use 4 equally spaced bolts perangle and tighten to 32Nm (23ft-lb).

6. Tighten all sheet bolts to 65Nm (46ft-lb).

7. The assembled top ring can now be lifted using

suitable lifting equipment fixed at four equally

spaced points around the pit top. While the pit is

suspended, remove the foundation angles and fit

the lower ring of sheets. Fit the foundation

angles with sealant, using tapered inserts at the

sheet overlap points.

8. Tighten all bolts to the correct torque.

9. Fillet all sheet edges both inside the pit and

outside.

10. The assembled pit can now be lowered into the

excavation and should be suspended clear of the

base whilst a crew member goes inside.

11. From inside the pit the crew member should

place concrete blocks in position under the

foundation angle ensuring they are on a level and

firm footing.

12. Check that the pipe opening is set to the centre

line of the main tank and lower the pit onto the

concrete blocks.

13. Check levels and shim until the pit is level to +

or 1.5mm (1 / 16 inch) with the shims provided

and the top of the pit is to the required finished

height (allowance for pit top or grid to be

included).

14. Place the reinforcing mesh in the base area,

ensuring correct concrete cover by supporting

the mesh with chairs/stools and then pour the

concrete into the pit centre. Ensure that the

concrete flows out underneath the foundation

angles by using a concrete vibrator. Ensure that

levels inside and outside the pit are correct by

referring to the approved pit drawing.

15. Compacted granular fill may be used in the pit

excavation to within 100mm (4 inches) of the

foundation angles, unless the distance betweenthe edge of the reception pit and the main tank is

less than 2.5m (8ft 3in), when it is then advisable

to backfill with concrete that half of the pit

excavation which is nearest to the main tank.

Determine the amount of compacted granular fill

required, taking into account that all inlet pipes

and anchor rods around the top of the pit are to

be encased in mass concrete. Refer to approved

pit drawings.




Doc Ref: P132 Rev 9 1 /5 /10 of 97

16. When the concrete has cured sufficiently, after a

minimum of 3 days, apply a surface primer to the

concrete base only, as shown, wait for it to

become tack free, then seal inside the pit with a

fillet of sealant between the concrete and Glass-

Fused-to-Steel sheet.

WARNING: Serious damage will result to the

Glass-Fused-to-Steel if a flame torch is used to

dry out base concrete to install the sealant seal.




Doc Ref: P132 Rev 9 1 /5 /10 of 97

PART SIX Section 1

Roof Construction



Permastore Construction Guide Roof Construction

Doc Ref: P132 Rev 9 1 /5 /10 of 97

INTRODUCTION


undertaken by competent building crew familiar



the responsibility of the building crew undertakingthese works to consider each particular


therein prior to commencement of work. To




carried out safely.

As a general rule all roofs should be constructed at

ground level.

Dependent upon the type of roof being installed, site

and environmental conditions and otherproject-specific factors, roofs can be constructed at

varying stages of the installation process.

In some extreme cases alternative methods of roof

construction may affect the roof design.

It is therefore extremely important to evaluate this

subject at the earliest opportunity and plan

accordingly.

The construction methods described within this

section may not apply to all installations.

For advice on alternative methods of construction

please contact Permastore.




Doc Ref: P132 Rev 9 1 /5 /10 of 97

PART SIX Section 2

Trough Deck Roof Construction




Doc Ref: P132 Rev 9 1 /5 /10 of 97

TROUGH DECK ROOF CONSTRUCTION











carried out safely.

NOTE: Roofs up to and including 8.53m (28ft)

diameter are constructed at low level before the tank

is jacked to full height. Roofs above 8.53m (28ft)

diameter are generally built following completion of

the tank.

1. Study drawing for layout of support brackets,

beam configuration, upright supports etc.

2. Pre-assemble beams if required.

3. Fix support brackets to top angle at positions

indicated on drawing.

4. Fit primary beams and uprights (where required)

ensuring correct location to provide a shallow

fall across the roof.

5. Fit secondary beams and tie rods if required.

6. Anchor vertical supports to base.

7. Position centre row of cladding across tank.

Pilot drill and fix with the self-tapping screws

provided.

8. Fit rest of cladding working from centre row

outwards. Refer to drawing for special panellayouts and overlaps. If access is required onto

any area of the roof that has already been clad

then spreader/crawler boards must be utilised

and safety rails fitted along any exposed edges.

Alternatively safety netting can be suspended

underneath the roof.

9. Trim off around edge of top stiffener angle using

a suitable portable nibbler or hand saw.

10. Seal between top stiffener angle and cladding

with aerosol canned foam (where required).

11. Fit perimeter flashing around the tank using the

self -tapping screws provided.

12. Check all coated parts for damage and repair if

necessary.

TROUGH DECK ROOF SHOWING BEAM END AND GRP FLASHING




Doc Ref: P132 Rev 9 1 /5 /10 of 97

PART SIX Section 3

20° Stainless Steel Roof Construction




Doc Ref: P132 Rev 9 1 /5 /10 of 97

20° STAINLESS STEEL ROOF

CONSTRUCTION




regard to Health and Safety. Furthermore, it isthe responsibility of the building crew undertaking







carried out safely.

1. 20° Roofs are constructed at ground level.

2. Assemble top ring of sheets as detailed with Part

Four Section 1.

3. Set roof cap centre support at the height specific

on the adjacent sketch, dependent on the roof

diameter.

4. Variations to tank height can also be calculated

using the combination of sheet heights identified.

5. Where special height sheets form part of the

supply these will be specified on the project

drawings.

6. Fit the centre roof cap onto the roof cap centresupport column.

7. For roof diameters 6.83m (22ft) and above the

panels are manufactured in two pieces and

panels should be pre-assembled prior to

construction.

8. The first panel fitted must overlap the sheet

vertical joint by at least one clear hole pitch.

9. Successive roof panels must be constructed in a

clockwise direction ensuring fitment of the

internal radial stiffener angles as each new panel

is installed.

10. Do not tighten the panels to the roof cap until the

whole assembly is complete.




Doc Ref: P132 Rev 9 1 /5 /10 of 97

SPECIAL NOTES

1. Fit tapered inserts on top of roof panel overlap

points before fixing to underside of roof cap.

Also at the roof panel to tank overlap points and

where the tank shell vertical joints overlap.




Doc Ref: P132 Rev 9 1/5/10 of 97

PART SIX Section 4

External Tapered Beam Roof Construction




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EXTERNAL TAPERED BEAM GLASS-FUSED-

TO-STEEL ROOF CONSTRUCTION











carried out safely.

1. Tapered Beam roofs are constructed at ground

level.

2. Assemble top ring of sheets including the topangle, as detailed in Part Four Section 1.

3. Set up suitable load bearing scaffold in the center

of the tank at the correct height to support the

roof during building.

4. Refer to assembly drawings for positions of

inserts, sealer plates, bolt lengths etc. Roof top

stiffener angle galvanised parts to be primed

with Sika Primer 210T along joint face and

allowed to dry before applying sealant.

EXTERNAL BEAM ROOF

5. To assist when hanging very large panels a hole

is punched for attachment of a special lifting

bracket. After fitting the panel apply sealant

around the hole, insert a store bolt and tighten to

65Nm (46ft-lb).

6. When assembling Glass-Fused-to-Steel roof

panels the bolt torque setting should be 65Nm

(46ft-lb) generally and 32Nm (23ft-lb) where

tapered inserts are fitted. 7. Check that centre support ring is level and set to

the correct height above the top stiffener angles.

8. Check roof layout for access upstand/flange

positions and walkways and proceed to install

the first four roof beams, placing them at 90°

intervals.

9. Assemble the next four beams in the centre of

the four beams already installed. Proceed to

assemble the rest of the beams using the same

technique.

10. When all beams are in position the roof panels

can be installed.

11. Proceed to fit outer roof panels in an

anticlockwise direction by slackening and

supporting the beams and inserting the panels

between the beam and the top angle, ensure that

the rubber inserts are correctly placed. It is

advisable to assemble at least three panels before

tightening and always leave two loose panels

between the one being installed and the one

being tightened.

12. Following completion of the outer ring of panels

commence installation of the inner roof panels,

again in a clockwise direction.

13. Apply sealant to upper surface of roof panel,

along all bolt seams except at the top (shortest)

edge. With suitable lifting equipment proceed to

lift roof panels into position and fix to under side

of beams installing all bolts in opposite sides of

adjacent beams and lower edge seam.

14. Complete the full ring of panels torque up bolts

in panel previously installed and apply sealant

fillet along the edges of this panel.

15. Proceed to assemble the roof using these

techniques on subsequent rings.

16. Apply sealant and fit roof cap plates together

with roof cap stiffener.

17. The centre annulus support scaffold must not be

removed until all roof panels are fitted.




Doc Ref: P132 Rev 9 1/5/10 of 97

PART SIX Section 5

External Parallel Beam Roof Construction




Doc Ref: P132 Rev 9 1/5/10 of 97

EXTERNAL PARALLEL BEAM GLASS-

FUSED-TO-STEEL ROOF CONSTRUCTION











carried out safely.

1. Paralled Beam roofs are constructed at ground

level.

2. Assemble top ring of tank sheets including thetop angle as detailed within Part

Four - Section 1.

3. Set up suitable load bearing scaffold in the center



4. Refer to assembly drawings for positions of

inserts, sealer plates, bolt lengths etc. Roof top

stiffener angle galvanised parts to be primed

with Sika Primer 210T along joint face and

allowed to dry before applying sealant.

PARALLEL BEAM ROOF

5. To assist when hanging very large panels a hole

is punched for attachment of a lifting bracket.

After fitting the panel apply sealant around the

hole, insert a store bolt and tighten to 65Nm

(46ft-lb).

6.

When assembling Glass-Fused-to-Steel roofpanels the bolt torque setting should be 65Nm

(46ft-lb) generally and 32Nm (23ft-lb) where

tapered inserts are fitted.

7. Check that centre support ring is level and set to

the correct height above the top stiffener angle.

8. Check roof layout for start datum and install

starter roof panels. Ensure that rubber inserts are

correctly positioned.

9. Install first four roof beams, placing them at 90°

intervals. Refer to sketches on the followingpage for details of beam end attachment.

10. Install next four beams central to the four beams

already installed. Proceed to install the rest of

the beams following the same procedure until all

beams are in position.

11. Following completion of the outer ring of panels

commence installation of the inner roof panels,

again in a clockwise direction.

12. Apply sealant to upper surface of roof panel, ie

along the bolt seams except at the top (shortest)edge. With suitable lifting equipment proceed to

lift roof panel into position and fix to underside

of beams installing all bolts in opposite sides of

adjacent beams and lower edges seam.

13. Complete the full ring of panels working in a

clockwise direction, torque up bolts in panel

previously installed and apply a sealant fillet

along the edges of this panel.

14. Proceed to assemble the roof using these

techniques on subsequent rings.

15. Apply sealant and fit roof cap plates together

with roof cap stiffener.

16. The centre annulus support scaffold must not be

removed until all roof panels are fitted.




Doc Ref: P132 Rev 9 1/5/10 of 97

PARALLEL BEAM END ATTACHMENT DETAILS




Doc Ref: P132 Rev 9 1 /5 /10 of 97

PART SIX Section 6

Glass Reinforced Plastic (GRP)Roof Construction




Doc Ref: P132 Rev 9 1 /5 /10 of 97

GRP ROOF CONSTRUCTION











carried out safely.

1. GRP roofs are constructed at ground level.

2. The design and shape of GRP roofs vary

considerably and for this reason the following

instructions are very generalised.

3. Set up suitable load bearing scaffold in the centre



4. Using a mobile crane, place first roof panel

positioning the panel onto roof support angles

and centre support scaffold.

5. Join remaining roof panels together installing

sealer strip or sealant in between joints and bolt

together using the stainless steel setscrews,

washers and nuts provided. Tighten inaccordance with the manufacturers instructions.

6. After installing all the roof panels drill out holes

in outer roof support flange to align with holes

already in outer roof support angles. Lift up roof

sheets from roof support angles using a pinch bar

or similar, clean out drill swarf, apply sealant in

between roof support angles and roof flange.

Install store bolts provided and tighten to 30Nm

(20ft-lb).

7. Place roof cap into position, drill through roofcap and roof panels with a suitable size drill to

accommodate the fixings provided. Remove

roof cap, clean drill swarf apply sealant, install

fixings provided and tighten in accordance with

the manufacturers instructions.

8. Do not remove centre roof support scaffold until

all bolts are in position and tightened around the

perimeter of roof and roof cap is correctly

installed.




Doc Ref: P132 Rev 9 1 /5 /10 of 97

PART SIX Section 7

Pressure Testing ofRoofs




Doc Ref: P132 Rev 9 1 /5 /10 of 97

PRESSURE TESTING OF ROOFS











carried out safely.

1. Where the project specification dictates a

pressurised roof these are designed to withstand

internal pressures and vacuums. Following

construction and hydrostatic testing it is

important to test the roof to ensure that it is

effectively sealed and meets the specified

test/specification conditions.

2. Equipment needed:-

a) Electric blower capable of pressure

required.

b) Electric extension cables to reach the top of

the structure.

c) Manometer ('U' tube water gauge).

d) Pipe connection kit.

e) Appropriate personal safety equipment.

f) Knapsack sprayer.

3. Seal all tank outlet pipe flanges and access

hatches.

4. Fill tank with water to operational level.

5. Install blower connection kit and pressurise roof

to test pressure.

ROOF PRESSURE TEST KIT

6. Use a water and detergent mixture to test all roof

seams and flange connections.

7. Pressure must be maintained during the period of

test, generally one hour maximum.

8. Mark any leaks that need to be repaired.

9. Release pressure from structure and repair any

leaks. If leaks were repaired, re-pressurise and

check they are sealed.

NOTE: It is advised that tests are carried out on

a calm and cloudy day. Variations in

temperature due to sun, rain or wind can greatly

affect internal pressure. These changes will

cause pressures to fluctuate and will need to be

compensated for during the test.

Extreme fluctuations may cause a serious

over/under pressurisation of roof resulting in

damage if venting is not adequate.

10. Ensure the roof is vented before draining internal

water to prevent implosion.

11. When pressure testing to specific test/contractual

conditions it is advisable to ensure the customer's

representative witnesses the test.

CAUTION: WHEN FILLING AND/OR

DRAINING A TANK IN PREPARATION FOROR FOLLOWING ROOF PRESSURE TESTING

IT IS IMPORTANT TO ENSURE THAT ROOF

INSPECTION HATCHES, VENTS, APERTURES

ETC ARE LEFT OPEN TO PREVENT AN

OVER-PRESSURE OR VACUUM SITUATION

OCCURING WHICH MAY RESULT IN

PERMANENT DAMAGE TO THE TANK

STRUCTURE.




Doc Ref: P132 Rev 9 1/5/10 of 97

PART SEVEN Section 1

Construction of

Glass-Fused-to-Steel Floors



Permastore Construction Guide Glass-Fused-to-Steel Floor Construction

Doc Ref: P132 Rev 9 1/5/10 of 97

GLASS-FUSED-TO-STEEL FLOOR

CONSTRUCTION

1. Prior to proceeding with the installation ensure

you have read and understood the layout

drawings for the type and size of floor to be

assembled. 2. From the centre point of the prepared foundation

mark a circle equivalent to the nominal tank

diameter plus 150mm (6 inches).

3. Mark out the 0°-180° and the 90°-270° centre

lines ensuring they are clearly identifiable

outside of the circle.

4. Lay base angles to confirm location of shim

packs and install shim packs to the CORRECT

radius and level.

5. Install the bitumen sand (asphalt/tank base)

within the tank circle as detailed on the layout

drawing and level with the shim packs.

6. Care must be taken to ensure the asphalt surface

is level. A slight rise to the centre is desirable.

7. Lay polythene sheet and cover asphalt before

installing floor.

8. Special care must be taken to protect the floor

panels during construction of the floor and tank.

9. Before each sheet is laid, insert the bolts inreadiness for fitting the adjoining sheets, secure

the bolts with the 'push on' fixing (Part Number

208059091).

10. Apply sealant ensuring a liberal covering around

the protruding bolts.

11. For Glass-Fused-to-Steel floors up to and

including 21.347m (70ft) diameter the perimeter

holes for fixing the floor to the foundation angles

are pre-drilled.

This is feasible due to the circular accuracy of

smaller diameter tanks.

12. For Glass-Fused-to-Steel floors above 22.2m

(73ft) diameter and above the perimeter holes

need to be drilled on site.

13. Lay the first panels (row 'D') and ensure that thefirst row of floor sheets is in a straight line

before tightening; very important on large tanks.

FLOOR LAYOUT

14. Lay subsequent panels in sequential order as

specified on construction drawing.

15. Fit tapered inserts at the sheet overlap areas

between the floor sheets and the base angles.

16. Fit full rows of sheets before tightening bolts

using the standard torque settings to assist with

alignment.

17. Fillet all sheet edges.

18. As there is no expansion pressure on a flat

surface it is not necessary to use a joint expanderduring construction.

19. For floors up to and including 21.347m (70ft)

diameter that are pre-drilled lay the perimeter

panels first and work inward.



Permastore Construction Guide Glass-Fused-to-Steel Floor Construction

Doc Ref: P132 Rev 9 1/5/10 of 97

20. Providing the procedures have been carefully

followed there should not be any cause for

leakage, however, it is advisable for the crew

leader to carefully inspect all areas of the sealing

joints and fillets. This may be your last chance

to ensure a seal.

21. Dependent on the method of construction for the

tank cylinder, protective nut caps should be fitted

now if not using jacks. Where jacks are being

used to construct the tank the nut caps should not

be fitted until after the tank is constructed and all

jack equipment removed.

22. Floor fixings should be treated with Sika Primer

210T and coated with sealant prior to fitting nut

caps.

23. Install the foundation angles and where they join

fit the joint sealer angles (Part Number 559299)as shown. Floor foundation angles joint faces to

be primed with Sika Primer 210T and allowed to

dry before applying sealant. Construct the first

ring of tank cylinder sheets in the conventional

manner.

24. Tapered inserts should also be fitted at the

vertical sheet joints.

25. Expand the vertical sheet joints before tightening

the bolts to 65Nm (46ft-lb).

FLOOR PLATE BASE ANGLE CONNECTION

26. Continue building the tank structure referring to

the relevant section of this guide.

27. When the structure is complete drill and fit the

foundation bolts and PVC isolation washers and

install the internal perimeter sealant fillet.

SECTION THROUGH FOUNDATION BOLT

28. Fillet the outside of the structure with concrete if

specified/required.

29. Fit plastic nut caps to the floor area if not already

installed.

30. The finished floor assembly MUST be wet swab

tested at this stage (Part Ten Section 2) and any

repair work undertaken. For details of suitable

repair procedures refer to Part Twelve Section 1

of this guide.




Doc Ref: P132 Rev 9 1 /5 /10 of 97

PART EIGHT Section 1

Cone Tank Construction



Permastore Construction Guide Cone Construction

Doc Ref: P132 Rev 9 1 /5 /10 of 97

CONE TANK CONSTRUCTION


undertaken by competent building crews familiar


regard to Health and Safety. Furthermore it is the

responsibility of the building crew undertakingthese works to consider each particular


therein prior to commencement of work, to




carried out safely.

Introduction

1. Cones and structures are designed to conform

with the product being stored and customer

requirements. The connection and designtechniques will remain similar.

2. Except for skirt mounted structures a crane will

be required to lift the structure and cone onto the

supporting steelwork.

3. Construction layout and techniques are the same

as standard tank design, ie joint overlap and bolt

torque.

4. A tapered insert is used at angle and sheet

transition overlap areas.

5. Cone structures are designed to be supported by

Glass-Fused-to-Steel sheets (skirt mounted) or

sectional steel (steel-frame mounted). The actual

design being determined during the enquiry stage

when the operational and storage details are

clear.

6. Skirt mounted cone structures can, in most cases,

be assembled using the conventional installation

equipment traditionally used to construct

Permastore tank and silos.

7. Steel frame mounted cone structures generally

require specialist lifting equipment to ensure a

quality and safe construction.

SKIRT MOUNTED STRUCTURES

1. Build tank structure as standard procedures

ensuring that for the final lift before the hip- joint

the jacks are taken down to their lowest position.

This will ensure the extra height required to

install the hip-joint. Lift jacks to their highest

position and check that clearance is sufficient to

assemble hip- joint and first row of skirt sheets.

2. Check all relevant drawings and assemble hip-

joint leaving out section at jack positions and

ensure that correct length bolts are used, do not

fit those where stiffener ring is to be connected.

Leave bolt finger tight.

3. Hang first row of sheets leaving out any bolts

where stiffener ring is to be fitted.

4. Lower structure onto support and disconnect jack

bolts.

5. Lower jacks and connect for next lift, raise

structure sufficiently to allow completion of hip

joint and fitting first row of cone sheets. After

tightening cone sheets assemble and fit external

stiffener. Raise structure again to hang second

row of skirt sheets.

6. Continue to build structure adding cone sheet

rings and internal stiffener brackets as required.

Fit internal stiffener on completion of skirt

sheets.

7. Fit cone outlet adapter to final row of cone

sheets before they are tightened.




Doc Ref: P132 Rev 9 1 /5 /10 of 97

8. Typical view showing the layout and assembly

of cone structure.

STEEL FRAME MOUNTED CONE

STRUCTURES

1. These structures are supported below the cone

hip-joints directly onto a steel superstructure and

will require a crane on site, time will be

dependent on method of build.

2. In most cases the top row of cone sheets would

be assembled on a firm, level area of ground.

Attach the cone support ring and cylinder base

angle.

3. Check that the ring of sheets are level, expand

the vertical seams and tighten. Do not tighten

the bolts from the cone support ring to base

angle at this stage.

4. Lift cone ring with crane using either internal

bracing or a spreader frame to prevent distortionof the ring. Further rows of cone sheets can be

added at this stage depending on the size of

crane employed.

5. Lift the cone onto the platform and bolt down.

Tighten all bolts in base angle and channel.

6. Choose a firm level piece of ground and build

the main structure using construction jacks.

Ensure that the jacks are securely anchored

down. Fit a suitable lifting bracket to each

vertical seam on the top row of sheets.




Doc Ref: P132 Rev 9 1 /5 /10 of 97

7. Using a spreader bar lift structure onto top of

cone and couple up. Ensure that a good sealant

fillet is applied inside to fully cover the hip- joint

area.

ALTERNATIVE METHODS OF CONE

CONSTRUCTION

1. The structure can be built by using the crane

instead of construction jacks. Build the top row

of sheets and roof on a suitable level piece of

ground. Fit lifting brackets and install other

rings of sheets while suspended.

2. Lift pre-assembled structure and couple to cone

at ground level before installing onto steel

platform.

3. After fitting the cone onto the platform, scaffold

can be placed internally and externally around

the top of the cone and steelwork and the main

structure built directly on top of the cone using

construction jacks. This system will require load

bearing scaffolding and special brackets

manufactured to support the jacks.




Doc Ref: P132 Rev 9 1/5/10 of 97

PART NINE Section 1

Construction of Ancillary Products



Permastore Construction Guide Ancillary Products

Doc Ref: P132 Rev 9 1/5/10 of 97

GENERAL GUIDANCE NOTES

The ancillary products contained within this part of

the Construction Guide have all been designed by

Permastore or have been technically assessed for

suitability with our standard product.

Although Permastore offer a comprehensive range ofancillary products there are situations where

customers manufacture their own ancillary products

or where unique process requirements dictate the use

of special equipment, fixtures and fittings.

It is extremely important to ensure the technical

suitability of any ancillary equipment that is not

supplied by Permastore and is to be mounted or fixed

to one of our structures. The un-necessary

introduction of dis-similar metals for example can

induce an electrolytic cell within the as constructed

tank.

Permastore cannot accept any responsibility for

problems associated with the attachment/fitment of

ancillary equipment by others unless those products

have been approved for use, in writing, by our

Engineering Department.

IF IN DOUBT, ASK.




Doc Ref: P132 Rev 9 1/5/10 of 97

PROTECTIVE NUT COVERS

1. Plastic nut covers are supplied as standard with

Glass-Fused-to-Steel floors, backfilled tanks and

inner annular tanks. They are provided to

protect the exposed fixings only where there is a

risk of contents or environmental corrosion.

They can also be purchased separately for

aesthetic purposes if required.

2. Check the relevant drawings for the position ofthe protective nut covers (eg backfilled tanks

have nut caps fitted in the area of backfill only,

unless otherwise specified).

3. Once the nut has been tightened to the final

torque, ensure that there is plenty of sealant

squeeze-out around the nut and washer, then

push the protective nut cover onto the nut and

washer. Use either a rubber or wooden mallet to

install tight caps.

4. If the sealant around the nut and washer has

cured, scrape off the cured sealant and apply a

bead of sealant to the inside of the protective nut

cove and push onto the nut and washer assembly.

FLANGE CONNECTORS

1. Flange connectors are available in a range of

options, the standard supply is detailed below:-

2. Refer to the assembly drawings for the correct

orientation/position.

3. When installing flange connectors, apply sealantaround the sheet aperture where the connector is

in contact with the Glass-Fused-to-Steel plate.

Position the connector and backing flange and fit

the fixing bolts. Tighten fixings to 50Nm (36ft-

lb).

4. Fillet the internal edges of the connector

assembly ensuring that the bore is not restricted

by sealant.




Doc Ref: P132 Rev 9 1/5/10 of 97

VENTS AND ROOF HATCHES

1. Pre-assemble vent or hatch if required.

2. Apply sealant around roof aperture where the

vent or hatch is in contact with the Glass-Fused-

to-Steel sheet. Fit and tighten fixing bolts to

50Nm (36ft-lb).

3. Glass reinforced plastic or aluminium fittings

should only be tightened to 30Nm (20ft-lb).

4. Steel fitments should be tightened to 50Nm

(36ft-lbs).

5. Fillet all internal and external edges with sealant.

TANK WALL ACCESS MANWAYS

1. Tank wall access manways are supplied as a

complete assembly including a pre-cut aperture

sheet and are designed to complement the

particular application required. The standardmanway is 800mm diameter with a hinged cover

to facilitate safe and easy access.

2. Dependent upon the specification supplied it

may be necessary to use a mobile lifting rig to

position the manway frame.

3. Apply sealant around the sheet aperture inside

and outside the tank, ensuring sufficient

coverage to effectively seal the flange plates.

4. Position the backing plate inside the tank and

insert a small quantity of fixings.

5. Position the external frame and fit nuts and

washers to the locating fixings.

6. Insert the remaining fixings and tighten to the

standard torque setting.

7. Fillet the internal and external edges of the frame

assembly ensuring effective edge protection.

8. Position and fix the access door ensuring ease ofoperation and effective closure.




Doc Ref: P132 Rev 9 1/5/10 of 97

LADDERS AND PLATFORMS

1. Ladders and platforms are supplied in various

configurations according to the height, diameter,

market standards and client specification. It is

therefore very important to refer to the assembly

drawing prior to construction to ensure thecorrect layout details.

2. Pre-assemble the ladder platform sections and

mark the position on the tank of the ladder and

platform support brackets.

3. Ensure the tank bolts have been omitted during

tank construction.

4. Apply sealant to the tank wall and support

brackets before installing the fixings.

5. The ladder sections and platform assembly can

then be fitted to the support brackets at low level

as the tank is being built.

6. Base ladders should be fitted to confirm

suitability but removed before leaving site and

handed to the client for safe storage.

Base ladders should only be fitted to

accommodate controlled access.

7. Install the platform base onto the relevant

support brackets and then complete the assembly

by fitting the upright support and handrails.

8. Several variations of the standard ladder and

platform options are shown for reference only on

the following pages.

SECTIONAL VIEW OF INNER AND OUTER

LADDER ASSEMBLY.




Doc Ref: P132 Rev 9 1/5/10 of 97

INDUSTRIAL LADDER AND PLATFORM OPTIONS

OPEN TOP TANK LADDER

ASSEMBLY

OPEN TOP TANK LADDER ASSEMBLY

WITH OPTIONAL 1M SQUARE

VIEWING PLATFROM

OPEN TOP TANK LADDER ASSEMBLY

WITH OPTIONAL 2M x 1M VIEWING

PLATFORM




Doc Ref: P132 Rev 9 1/5/10 of 97

AGRICULTURAL LADDER AND PLATFORM OPTIONS

OPEN TOPPED AGRICULTURAL TANK LADDER ASSEMBLY WITH OPTIONAL 2M x 1M (6ft x

3ft) PLATFORM WITH CENTRE FLOOR HATCH

5 RING TANK 4 RING TANK 3 RING TANK




Doc Ref: P132 Rev 9 1/5/10 of 97

CIRCUMFERENTIAL LAUNDERS

1. Launders are used to remove clarified or settled

liquids from the top of process tanks.

2. Within our standard range of ancillaries there are

two distinctive systems available.

'Z' TYPE LAUNDER SYSTEM

3. 'Z' type launders are mounted directly onto the

tank wall with a separate scumboard assembly.

4. Ref er to all relevant drawings before

commencement of work to ensure correct

assembly layout. Launder systems should be

fitted at ground level.

5. Position first launder section at correct height

and central to the outlet flange. Some launders

may incorporate a special dropped outlet. Locate

this section first.

6. Where a GRP 'Z' type launder is being installed

drill holes 14mm (½ inch) diameter through the

launder trough section using the holes in the

Permastore sheet as a template.

7. Apply sealant to mating face of launder trough

and Permastore sheet, fit launder in place andbolt in position.

8. Proceed to fit launder trough around tank in an

anti-clockwise direction ensuring that each

section is bolted together with sealant and

fixings.

9. The last section of launder trough may need

trimming (GRP only) on the plain section end to

ensure correct joint with outlet section.

10. Fit weir plates in position at the correct level

ensuring the sealer strip is effectively placed to

avoid seepage.

'U' TYPE LAUNDER SYSTEM

11. 'U' type launders are mounted on brackets with

an internal scum board.

12. Refer to all relevant drawings before

commencement of work to ensure the correct

assembly layout. Launder systems should be

fitted at ground level.

13. Install mounting brackets as detailed around the

perimeter of the tank.

14. Position the first launder section central to the

outlet flange. Some launders may incorporate a

special drop box. Locate this section first.

15. Proceed to mount launder trough on the support

brackets around the tank in an anti-clockwise

direction, ensuring that each section is bolted

together with sealant and fixings supplied.

16. Fix launder trough to mounting brackets usingpre-punched holes, ensuring good sealant

application around fixings.

17. Fit weir plates in position at the correct level

ensuring the sealer strip is effectively positioned

to avoid seepage.




Doc Ref: P132 Rev 9 1/5/10 of 97

BAFFLES AND BAFFLE WALLS

1. Internal baffle assemblies are utilised to provide

a homogenous mixture of contents in process

tanks.

2. Directly dependent on the height of the tank the

baffle assembly may be designed as a single

price structure or a modular concept.

3. Refer to all relevant drawings before

commencement of work to ensure correct

assembly layout. Baffle assemblies and baffle

walls should be installed at ground level.

4. Apply sealant to the contact surfaces and fit

vertical support angle frames to the tank wall.

5. Fit Glass-Fused-to-Steel baffle plates to the

angle frame.

BAFFLE WALL

1. Baffle walls are utilised to separate different

sections or processes within a tank.

2. Apply sealant to contact faces and fit vertical

support angles to inner and outer tank.

3. Fit baffle wall to support angles.

4. Fit top angle to baffle wall using splice plates to

join to inner tank.

5. After fitting floor angles drill out concrete and fit

expanding anchor bolts.

6. After completion of baffle walls install concrete

haunch over floor angles if specified.

7. Apply sealant to contact faces and fit weir weld

assembly to inner tank.

8. Fit splice plates to weir weld assembly to join to

top stiffener angles.




Doc Ref: P132 Rev 9 1/5/10 of 97

AGRICULTURAL VALVE KIT (SLUICEGATE)

1. Refer to approved valve assembly drawings.

2. When installing the valves and trunking or

pipework, ensure any PVC joints are glued

correctly.

3. Support the pipe or trunking and valves in the

trench, to allow a minimum of 150mm (6 inches)

concrete cover over the pipework.

4. Valves must be installed with flow direction

arrow facing the reception pit to ensure that the

valve plate is under flow pressure against the

seal.

5. Wrap the entire length of PVC pipework in

polythene sheeting.

6. Care should be taken when pouring the concreteto ensure the pipework or trunking is not

disturbed or damaged.

7. Concrete clearance must be maintained at the top

of the valve to allow for top plate removal.

8. Fitting the outlet into the reception pit may

require the cutting of the Glass-Fused-to-Steel

sheet (Refer to Part Eleven Section 1).

SACRIFICIAL ANODE CATHODIC

PROTECTION SYSTEM

1. There are some applications where the process

requirements or commercial factors dictate that

routine inspection and maintenance is

impractical. Where such conditions existPermastore recommends that a suitable cathodic

protection system is installed, monitored and

maintained. Cathodic protection systems can

provide a low cost, long term solution to protect

your investment.

2. For further information please refer to Document

Ref: P145 'Guidance Notes for the Application

and Use of Sacrificial Anode Cathodic

Protection Systems'.




Doc Ref: P132 Rev 9 1 /5 /10 of 97

PART TEN Section 1

Checklist Following Construction



Permastore Construction Guide Checklist

Doc Ref: P132 Rev 9 1 /5 /10 of 97

CHECKLIST AFTER CONSTRUCTION

1. Ensure sufficient sealant has been applied

correctly.

a) To provide full cover to all areas of sheet

overlap;

b) To provide a squeeze out of sealant around

bolt heads, nuts and washers.

2. Have bolts been fitted to all holes used for joint

expansion or jack location?

3. Have all sheet edges been pointed correctly to

give full protection both internally and

externally?

4. Have all ancillaries attached to Glass-Fused-to-

Steel coated sheets been fully coated with sealant

on contact surfaces before being bolted?

5. Have tapered inserts been used in appropriate

areas at top and bottom angles?

6. Are the levels and concentricity in accordance

with recommendations?

7. Are all the bolts within the specified torque

limits?

8. Has the peripheral base seal been applied

correctly and checked for adhesion?

9. Are all ancillary items securely fastened?

10. Has the full structure been examined carefully

and swab tested internally to identify any

installation damage and have the damaged areas

been repaired? The application of this test must

be witnessed by the customers site representative

following which the 'On Site Wet Swab Testing

Results Chart' (Doc Ref: 02.04.02 Appendix 7)

and the 'Certificate of Completion' (Doc Ref:

02.04.02 Appendix 4) must be authorised by the

sub-contractor and the customers representative.

For full instructions on repair procedures refer tothe Permastore Inspection and Maintenance

Manual Document Reference P110.

11. Check serial plate has been fitted.

12. Check that the Safety Awareness signs provided

within the tank construction kit are installed as

instructed (refer to Item 6, of 'Forward' Section

of this guide)

13. Ensure the structure has been left in a safe and

secure condition for following operations/testing.

For example:

a) Base ladders removed and stored safely by

the client.

b) Access doors fitted/closed correctly

c) Pressure test blanking plates removed.

d) No debris/fixings left in the tank that coulddamage process equipment.

e) Any other obvious or client specified

activities.

13. Ensure all packing and waste materials have

been cleared up, disposed of properly and the

site is left tidy. All COSHH substances and

contact packaging must be disposed of in a safe

manner commensurate with the manufacturers

data sheet.

14. Inspect the structure with the customer'srepresentative and assuming everything is in

order request his authorisation of a Construction

Completion Certificate.




Doc Ref: P132 Rev 9 1 /5 /10 of 97

PART TEN Section 2

Low Voltage Continuity Testing on Site



Permastore Construction Guide Testing on Site

Doc Ref: P132 Rev 9 1 /5 /10 of 97

LOW VOLTAGE CONTINUITY (WET SWAB)

TESTING ON SITE

All structures should be wet swab tested on the

internal surface following construction.

We recommend that for tall structures being built with jacks, that a check on the continuity of the internal

Glass-Fused-to-Steel coating is conducted on a ring

by ring basis during construction.

This will identify any minor repairs that may be

necessary following construction and will reassure the

end user that the product has a defect free

containment surface.

It is important to advise the customer's site

representative prior to testing, giving sufficient time

for the test to be witnessed and approved following

completion.

The internal surface of the structure should be clean

and free of surface contaminants. Testing is carried

our using an Elcometer Model 269 Wet Swab Unit set

at 9 volts. The test sponge shall be wet but not

saturated with water containing a small amount of

detergent to reduce surface tension.

In the unlikely event that a discontinuity is found the

following repair procedure should be adopted.

The identified area will be inspected for any signs of

corrosion. Should corrosion be evident the area must

be treated locally with Corroguard, abraded and then

allowed to dry for a minimum of 6 hours and then

overcoated with a 2mm ( inch) thick layer of sealant

overlapping the discontinuity area by 20mm (¾ inch)

all round.

The area of repair will again be subjected to low volt

test proving satisfactory repair.




Doc Ref: P132 Rev 9 1 /5 /10 of 97

PART ELEVEN Section 1

Troubleshooting



Permastore Construction Guide Troubleshooting

Doc Ref: P132 Rev 9 1 /5 /10 of 97

TROUBLESHOOTING

Introduction

This section has been compiled to assist the

construction team to resolve minor assembly issues

and undertake replacement or modification work.

One of the features of a Glass-Fused-to-Steel bolted

construction tank is the ability to modify the structure

on site to accommodate new or changed process

conditions. It is also possible to extend some

structures in height using either a top or bottom

extension but in all cases reference should be made to

Permastore to ensure suitability of proposed change.











carried out safely.

LEAKAGE REPAIRS

WARNING: If the structure has been in use there

may be potential hazards from toxic gases or

substances.

Please refer to the Health and Safety information

included within the Foreword of this guide.

In the unlikely event that leaks are in evidence on the

structure it may only be possible to effect a reseal

from the inside. The structure must then be drained

completely and the affected area thoroughly dried

before commencement of repair.

NOTE: Should the leak appear on the outside at a

bolt, the source of the leak is not necessarily at the

bolt head but may start through the sheet overlap.

Should the leak appear on the outside at a sheet

overlap the source of the leak is not necessarily at the

same point of the sheet overlap but may start from the

bolt head.

1. Bolt or Seam Leaks

a) To repair, mark the point of the leak

precisely on the outside of the tank before

draining the tank.

b) After draining the tank remove completely

all structure bolts and internal sealant filletwithin 150mm (6 inches) of the leak. Insert

fresh sealant into the bolt holes (from the

inside of the structure) and cover the bolt

head area of the sheet liberally with sealant.

c) Re-insert the bolts and tighten to the

prescribed torque. Replace the internal

sealant fillet and repoint.

d) Should the leak be serious, ie more than adribble, it may be necessary to part the

sheets with a small hard wooden wedge and

insert sealant to the complete overlap area

with a pallet knife.

2. Corner Joint Leaks

a) Remove existing sealant around the corner

joint extending beyond the nearest bolt in

all four directions.

b) Remove the corner bolt completely and

slacken the four bolts immediatelysurrounding the corner bolt.

c) Wedge open the joint internally with a hard

wooden wedge and inject sealant into the

open joint.

d) Repeat point (c) externally.

e) Replace the corner bolt, nut and washer.

f) Tighten the corner and four surrounding

bolts to the specified torque.

g) Re-point the corner joint and surrounding

seams with new sealant.

3. Perimeter Seal Leaks

If the leak is from the base area, again remember

that the point of the leak showing externally is

not necessarily the source and may start from

any point of the perimeter seal up to 3m (10ft)

from the leak. The source may also be from an

area of the floor because of porous concrete. For

perimeter seal leaks:-

a) Check the adhesion to the tank wall and

concrete foundation.

b) Suspect areas should be cut away 500mm

(18 inches) either side of the affected area

and the concrete cleaned and dried.

c) Apply concrete primer as specified for each

type of perimeter seal.

d) Apply new sealant to the area cut away.

NOTE: For all sealant repairs allow a minimum

of 10 days to cure before refilling the tank. For

temperatures below 15°C an extended cure

period will be required.




Doc Ref: P132 Rev 9 1 /5 /10 of 97

REMOVAL OF FLAT SPOTS ON THE

CORNER JOINTS OF A STRUCTURE

1. Remove all bolts surrounding the four corner

joints, clean, apply new sealant in the joints and

loosely install new bolts.

2. Secure a wooden support inside the tank with aM10 ( inch) diameter eye bolt through bolt

hole in sheer joint and pull out flat spot to the

correct shape of the tank. This is best done using

a chain block or similar anchored to a suitable

pulling point. After pulling out flat spots tighten

bolts to the correct torque. Remove chain block,

replace eye bolt and apply sealant fillets to blend

in with the existing fillets.

REMOVING AND REPLACING A GLASS-

FUSED-TO-STEEL SHEET

WARNING: If the structure has been in use there

may be potential hazards from toxic gases or

substances.



1. Set up scaffold to a working height on the

outside and inside of tank adjacent to where

sheet is to be removed.

To remove the sheet, carefully take out all the

sheet fixing bolts from the sheet overlaps. Itmay be necessary to remove the bolts on

adjoining sheets at the four sheet overlap joint

for the distance of about 300mm (12 inches).

Using wooden wedges gently prise the sheet

joints apart. Using suitable lifting equipment

remove tank sheet. Thoroughly clean sealant

from the sheet overlap joints.

2. To fit replacement tank sheet, sealant must be

applied to all the overlap faces and with wooden

wedges prise a gap between the adjoining sheets

as with removal. When the replacement sheet islowered into position with suitable lifting

equipment, ensure sealant is applied between the

prised open joints and applied to the replacement

bolts before fitting.

When all bolts are fitted tighten to the standard

torque and apply sealant fillets over sheet edges

to blend in with the existing fillets.

DRILLING AND CUTTING HOLES IN GLASS-

FUSED-TO-STEEL SHEETS

WARNING: Do not use disc grinders or flame-

cutting equipment to cut holes in Glass-Fused-to-Steel

sheets. Always use electric drill and jig-saw.

Always use eye protection when cutting or drillingsheets.

If the structure has been in use there may be potential

hazards from toxic gases or substances.



DRILLING HOLES

Mark the position of the hole to be drilled and dot

punch the centre. Start with a small pilot drill and

gradually increase the drill size to the required size tothe required hole diameter.

CUTTING OPENINGS

1. Apply masking tape over the areas of the

openings to be cut. Mark out the opening and

dot punch the inside edge. Drill out to 10mm

(13 / 32 inch) and using a jig-saw cut around the

marking opening. Recommend Bosch blades

type T118B.

2. After cutting or drilling remove all traces of

swarf and burred edges.

3. Ensure that all edges have been covered with

sealant on completion of work.

PERMASTORE REPAIR KIT

INSTRUCTIONS FOR USE

1. Corroless EP is a two part glass reinforced rust

stabilising primer.

2. Surface Preparation

Steel should be clean and free from any looseGlass-Fused-to-Steel coating, oil, grease or rust.

Abrade the surface and surrounding 25mm (1

inch) of sound Glass-Fused-to-Steel with

medium grit emery cloth.




Doc Ref: P132 Rev 9 1 /5 /10 of 97

3. Mixing and Application

Mix the two components at a 1:1 ratio and apply

without delay using a small, clean brush. Ensure

that the material overlaps onto the abraded

Glass-Fused-to-Steel. Do not over brush.

Externally applied repairs should be over paintedthe next day with locally sourced enamel paint to

match the Glass-Fused-to-Steel.

Internal repairs should be covered the following

day with the build sealant. Ensure the sealant

completely covers the repair material and

extends a minimum 20mm (¾ inch) beyond the

repair site.

4. Properties

Mix ratio 1:1 (by volume)

Working life 45 mins (at 18°C)

Drying time Touch 6 hours

Hard 16 hours

Over coating Min 16 hours

Max 3 days

Application temp Min 2°C

Max 30°C

5. Handling Precautions

Precautions normally taken when handling

chemicals should be observed. The material

must not come into contact with foodstuffs or

food utensils. The use of protective clothing,

goggles, barrier cream and rubber gloves arerequired. Adequate ventilation of the work area

is recommended. Leaflets are available on the

handling of these materials and we strongly

advise they are read prior to using the products.

6. Data Sheets

Material Safety and data sheets for all sealants,

primers and cleaners used to build Permastore

structures are generally provided with the project

documentation but are also available on request.

Whilst every care has been taken to ensure accuracy throughout this guide Permastore shall have noliability for any loss or damage, (direct or indirect or consequential) arising out of or in connectionwith this guide.

This guide is subject to supplementation or change at any time without notice at Permastore's solediscretion.

© Copyright 2009 Permastore Limited



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Permastore Construction Guide

Documents

Transcript of Permastore Construction Guide