Floating rooF design

June 2011 TA N K S T O R A G E

External floating roof or full contact internal floating roof? These tests
compare emission levels, maintenance costs and the impact the
Issue 1 - May 2009

decision has on working volumes

Decision time
Technical Articles
Floating Roof Design

Impact on Working Volume, Emissions and Operating Costs

Floating roofs have been in existence for over half a century, providing operators and regulatory bodies a reliable,
time proven safety and emission control system. Floating roofs function by reducing the formation and release of
environmentally harmful and potentially explosive volatile organic chemicals in above ground storage tank
loating roofs have
systems.
Typical floating roof designs

been in existence for

Floating
generally
over roof
half adesign
century,
varies with
the material
providing
operators
andused for
construction.
External floating
regulatory bodies a reliable,
roofs which are exposed to the
time
proven
safety
and
elements use carbon
steel
emission
control
system.
construction
with
pontoon or
double
deck generally
designs. varies
These
The design
designs
the floating
with
the allow
material
used forroof to
support potentially heavy loads of
construction.
External floating
rain and snow and are also usually
roofs
which
are exposed
tofrom
coated
to prevent
corrosion
the
elements
use carbon
weather
exposure.
Carbonsteel
steel
floating roofs
use
heavy orleg
construction
with
pontoon
supports
when
landed as well as
double
deck
designs.
large air-filled 'compartments'
These
designs allow the
known as pontoons for buoyancy.
floating
to steel
support
Externalroof
carbon
floating roofs
potentially
heavy some
loads of
rainof
also incorporate
form
articulating
pipe
oralso
flexible
hose
and
snow and
are
usually
deck drainage
system
to remove
coated
to prevent
corrosion
excess
precipitation
from their
from
weather
exposure.
surface.
Carbon steel floating roofs
use
leg supports
For heavy
tanks that
use fixed covered
when
as well
as roofs
large or
roofs,landed
like steel
cone
aluminumcompartments
geodesic domes, the
air-filled
internalas
floating
roof for
systems are
known
pontoons
typically constructed using lightbuoyancy.
External
carbon
weight materials because they
steel
also
don'tfloating
have roofs
to support
the
incorporate
some
of on the
environmental
loadsform
placed
external floating
systems.
articulating
pipe orroof
flexible
Whiledeck
materials
vary,
internal
hose
drainage
system
to
floating roofs typically use
remove excess
precipitation
The difference
between
a
carbon
aluminum as their structural
from
their
surface.
steel external
floating
material,
though roof
someand
use a
For tanks thin
that gauge
use fixed
fiberglass,
stainless
internal floating
roof
volume
loss
steel or roofs,
other composite
panels.
covered
like steel cone
height isroofs
anywhere
from
roughly
Depending
on
design,
internal
or aluminum geodesic
floating Depending
roof systems can
36 to 54.
onusually
tank
domes,
the
internal floating
be cable supported from the tank
roof
are
typically
diameter,
that
represents
fixedsystems
roof structure,
due to their a
constructed
usingof
light-weight
low mass.
significant
amount
working
materials because they do
volume loss
for
identical
sized
Onehave
of theto
key
differences
not
support
the between
tanks withstorage
carbon steeltanks,
external or
above ground
environmental loads placed as
aluminum internal floating roof is
shown inon
Image
2.
the working
external
floating roof
their
volume.
Each
systems.
While
floating roof
has materials
a differentvary,
cross
internal floating
roofs typically
With all floating
roof systems,
the
use aluminum as their
floating roof has to remain floating
structural material, though
and not some
landuse
tofiberglass,
work effectively.
thin
Floating
r ostainless
ofs ta
n k or
s other
have
gauge
steel
composite
panels.
restrictions
on how
highDepending
you can fill
design,
internal floating
the tankonwith
product.
External
roof systems can usually be
floating cable
roofsupported
systems
need
to
from the
operate tank
below
the
tank
shell
or
fixed roof structure,
foam ports.
floating roof
due toInternal
their low mass.
One of not
the key
differences
systems must
make
contact
between tanks
with the underside
ofwith
the atank fixed

- May 2009

External Floating Roof

Internal Floating Roof

(Image Courtesy of Mesa Rubber)

(Image Courtesy of Sandborn Roofs)

carbon steel external or

only support environmental
Imagefloating
1 - Typical Floating
Roof but
Designs
aluminum internal
live loads
also their own
roof is their working volume.
mass, which varies from
Each
floating
has a volume
about
12floating
to 16psf.
sectional
area roof
displacing
Internal
roofsPontoon
do not have
that wouldcross
otherwise
be filled with
a n y d i rvaries
e c t ebased
x p o s uon
re to
different
sectional
thickness
stored
product, translating
into lost
environmental
loads
like rain
area
displacing
volume that
design
and tank
diameter
butor
working volume due to the profile
snow, and ranges
are typically
very
would
otherwise be filled with
generally
from
32light
to in
depth of the floating roof system.
mass, varying from about 1 to 2.5
stored product, translating
48
in
depth.
The
weight
of
psf. Internal floating roofs use
into
loststeel
working
volume
the
floating
roof will
immerseor
Carbon
external
floating roofs
either
air filled
aluminum
due
theperimeter
profile depth
of to
the
pontoon
use to
large
pontoons
stainless
steelanywhere
pontoons, from
air filled
not floating
only support
environmental
honeycomb
or composite
the
roof system.
4-12.
Also,panels
external
floating
live
loads but
alsoexternal
their own mass,
foam require
filled panels
for and
buoyancy.
Carbon
steel
roofs
primary
which varies from about 12 to 16
Air filled pontoons vary in size but
floating
roofs use large
secondary
perimeter seals
psf.
Pontoon thickness varies
are typically eight to ten inches in
perimeter
pontoons
to diameter
not
to
reduce emissions
in the
based on design
and tank
diameter
and immerse
in the

Technical Articles

roof or support rafters. As a result,

the net capacity of tanks is
restricted to a certain minimum

rim area (area between the

pontoon and tank shell wall).
The primary seal is typically
contained within the pontoon
rim area while the secondary
seal extends anywhere from
18-24 above the pontoon
level. For external floating
roof pontoon designs, that
total volume loss profile
equates to about 42-72 or
more above product level.
Internal floating roofs do
not have any direct exposure
to environmental loads like
rain or snow and are typically
very light in mass, varying
from about 1 to 2.5psf.
Internal floating roofs use
either air filled aluminum
or stainless steel pontoons,
air filled honeycomb panels
or composite foam filled
panels for buoyancy. Air filled
pontoons vary in size but are
typically 8-10 in diameter
and immerse in the stored
product approximately 4-5

but generally ranges from 32 to

product approximately 4 to
Tank stored
working
volume floating roof design
48 in depth.
The weight of the
5 inches. Honeycomb Panels or
floating roof will immerse the
composite foam filled panels float
pontoon anywhere from
4 to
12.
in full contact with the liquid
Elevated
Liquid
Surface Temperature
Fixed Roofs Shelters product
Directrequire
Sunlight
Also, external floating in
roofs
surface and only immerse into the from Direct Sunlight
primary and secondary
perimeter
product
by
about

to
1. and wind effects.
Elevated Seal Losses caused by wind
and vacuum
seals to reduce emissions
in effect.
the
Internal floating roof systems only
Sealed Cables
rim area (area between the
require a single liquid mounted
No Emission Paths
seal, which typically extends above
pontoon and tank shell wall). The
the liquid level by 8 to 12. For
primary seal is typically contained
Emission Paths
Max Fill
Height
internal floating
roof
a design and
within the pontoon rim area while
at Leg Locations
depending on the perimeter seal
the secondary seal extends
system used the total volume loss
anywhere from 18 to 24 above
profile will vary from about 9 to
the pontoon level.
For external
18 above product
floating roof pontoon designs, that
36 ~ 54level.
Loss
total volume loss profile equates to
about 42 to 72 or more above
product level.

www.sandbornroofs.com

Low Fill Height

Steel Pontoon
External Floating Roof

Full Contact
Internal Floating Roof

Image 2 - Tank Working Volume by Floating Roof Design

81

drainage
systems.onPerimeter
seals
EFR systems
the same
sized
onFloating
both
designs,
tank
and
operatingexternal
low/high or
level
rooF design
internal
floating roofs may require
conditions.
Chart A: the difference in
in netapproximately
operating volume between a 10
replacement
pontoon EFR system and full Chart
contact IFRsystem
A perimeter
to 20 year cycles. EFR
150' dia. x 48' Shell
Barrels % Volume
seal
systems are larger151,092
than IFR
100%
Total Tank Capacity
seal
systems
and are significantly
113,319
75%
Steel
Pontoon EFR
124,336on an
82%
Full Contact
IFR
more
expensive
to replace
Difference
11,017
7%
on-going
Some
storage
Based on 3-6basis.
Operating,
4-0 HeadIFR
Loss 54
EFR vs 12 IFR
Based Low
on 3'-6
Low Operating,
4'-0 Head
Loss
54 EFR
vsseveral
12 columns
IFRconditions including
tanks
several
steel
to
inches.use
Honeycomb
Panels
or composite foam filled
tank turnovers (shell losses),
support
the fixed steel
cone roof
panels float in full contact
vapour pressure, atmospheric
with the liquid
conditions
and
system,
sosurface
each column
will(heat/wind)
have a
and only immerse into the
floating roof design. The
product by about 0.5-1. penetration
floating roof components
corresponding
seal
Internal floating roof systems
affecting emission loss
that
replaced
at the
only are
require typically
a single liquid
include the perimeter
seal
mounted seal, which typically
design (single/double),
same
as
seal
extendstime
above the
liquidthe
level perimeter
support type (legs/cables/
by 8-12. For an internal
grid), penetration seals
system.
floating roof, depending on
for columns and ladders, as
the perimeter seal system
used, the total volume loss
profile will vary from about
9-18 above product level.
The difference between
a carbon steel external
floating roof and an internal
floating roof volume
loss height is anywhere
from roughly 36-54.
Depending on tank
diameter, that represents a
significant amount of working
volume loss for identical sized
aboveground storage tanks.
With all floating roof
systems, the floating roof has
to remain floating and not land
to work effectively. Floating
roof tanks have restrictions
on how high the tank can be
filled with product. External
floating roof systems need
to operate below the tank
shell or foam ports. Internal
floating roof systems must
not make contact with the
underside of the tank fixed
roof or support rafters. As
a result, the net capacity of
tanks is restricted to a certain
minimum (low) and maximum
(high) operating levels.
Chart A shows the difference
in net operating volume
between a pontoon External
Floating Roof (EFR) system
and full contact Internal
Floating Roof (IFR) system. In
this example, the IFR systems
adds 7% more net tank
operating volume compared
to the EFR systems on the
same sized tank and operating
low/high level conditions.
Floating roof design also
has a significant impact on
the total amount of volatile
organic chemicals (VOCs)
product emission losses.
VOC emissions vary based on

well as the floating roof deck

construction (if its bolted/
welded/sealed together).
Carbon steel EFR systems
require steel legs for supports
when landed due to their
significant mass. Most EFR
systems use an adjustable
leg with support collar
penetration sleeves to allow
the operators to increase or
decrease the landed height
from low operating to a
higher maintenance position
allowing clearance for workers
underneath. Adjustable leg
supports provide an emission
path for VOC vapours to
escape into the atmosphere.
Aluminum internal floating
roofs can use thinner legs
supports or suspended
cable supports from the
tank fixed roof. Suspended
cable supports are adjusted
from the top of the tank
fixed roof and have no
emission paths from the
sealed deck connections.
External floating roofs
are also subject to higher
overall emission losses due
to the heating effects of solar
radiation and vacuum effects
of wind travelling across
the top of the tank.
internal floating roofs (IFR)
are sheltered from the direct
wind and sunshine and
as a result environmental

External floating roof system tanks

require a drain system, consisting
of either an articulated pipe or
flexible hose to drain the rainwater
and melted snow off the surface of

Issue 1 - May 2009

r odrain
o f systems
c o m p o non
e natlarge
s a f215'
f e c txi n g
and
losstank
include
60'emission
diameter
inthe
20perimeter
year
TA N K S T O R A G E June 2011
seal
design
(single/double),
service intervals.
Chart support
C: The approximate type
maintenance(legs/cables/grid),
costs of replacing the
perimeter seal, penetration seal and drain systems on a large 215 x
penetration
seals
for columns and
60 diameter tank in 20 year Chart
service intervals
C
ladders, as well asMaintenance
the floating
Costsroof
Materials
d e c k c o n sYears
t r u c t 20
i o n ( 40
if its
Steel
Pontoon EFR Perimeter
bolted/welded/sealed
together).
$144,700
$289,400
Seals & Hose Drain

Full Contact IFR Perimeter

$54,700 $109,400
Carbon
Seals
& Columnssteel
Seals EFR systems require
steel legs for
supports
when
landed
Difference
$90,000
$180,000
*Materials Only, Averaged based on 20 year lifespan of seal & drain
*Materials Only, Averaged based on 20 year lifespan
materials. 215 dia. x 60 Tank Size. 2008 Pricing. US Dollars

due to their significant mass.

of seal & drain materials. 215' dia. x 60' Tank Size.
Most
EFR
systems
an
factors
have a much
smaller
notDollars
leak and resultuse
in
2008
Pricing.
US
impact on the VOC emission
rainwater contamination
leg with
support
lossadjustable
on IFR tanks.
of the stored
product or collar
In
this
the
on-going
seal
Chart
B is example,
a sample VOC
possible
contamination
penetration
sleeves
to
allow
the
emission calculation for a steel
of groundwater (and the
maintenance
costs
of
the
IFR
leg aupported
pontoon EFR
corresponding
costs).
operators
tofull increase
ordisposal
decrease
versus a cableis
supported
Chart C shows
the the
system
approximately
37%
contact
aluminum
IFR system height
approximate maintenance
the
landed
from low
on the same size tank.
In this of
coststhe
of replacing
equivalent
costs
EFRthe seal
sample, the EFR equipped
perimeter seal, penetration
maintenance.
Depending
on the
tank system shows 27%
seal and drain systems
higher emission rates than the
on a large 215ft by 60ft
design
and construction
quality of
IFR equipped tank system.
diameter tank in 20 year
Another
impact of floating IFRservice
intervals.
the
aluminum
system,
their
roof design is the ongoing
In this example, the onmaintenance costs
for the
going
maintenance
expected
life-span
cansealbe
as long
floating roof seals and
costs of the IFR system is
as
their
steel EFR counterparts.
drainage
systems.
approximately 37% the
Perimeter seals on both
designs, external or internal
floating roofs, may require
replacement in approximately
10 to 20 year cycles.
EFR perimeter seal systems
are larger than IFR seal
systems and are significantly
more expensive to replace
on an on-going basis. Some
IFR storage tanks use several
steel columns to support the
fixed steel cone roof system,
so each column will have a
corresponding penetration
seal that is typically replaced
at the same time as the
perimeter seal system.
External floating roof
system tanks require a drain
system, consisting of either
an articulated pipe or flexible
hose to drain the rainwater
and melted snow off the
surface of the floating roof.
These drainage systems
need to be replaced
after a few maintenance
cycles to ensure they do

Technical Articles

equivalent costs of the EFR

seal maintenance.
Depending on the design
and construction quality of
the aluminum IFR system,
their expected life-span
can be as long as their
steel EFR counterparts.
While these comparisons
concern floating roof design,
tank operators will have to
weigh the operational and
lifetime benefits versus
the difference in capital
costs of tank construction
between the two systems.
Both systems offer industryproven solutions to safe
storage of VOCs, however the
floating roof design and its
ongoing maintenance costs,
emissions and operational
limits all play an influential
part of the process of deciding
which system provides
the best solution. n
For more information:
www.sandborn.ca

Chart B: a sample VOC emission calculation for a steel leg supported pontoon EFR versus a cable
Chart B
supported full contact aluminum IFR system

Type
Years
Steel Pontoon EFR
Full Contact IFR
Difference

1
7,480
5,490
1,990

Emission Losses (lbs per Year)

5
10
15
20
25
37,400 74,800 112,200 149,600 187,000
27,450 54,900 82,350 109,800 137,250
9,950 19,900 29,850 39,800 49,750

Based on Crude OilBased

(RVP on
5),Crude
Results
generated
from
EPA Tanks
Software
215 dia. x 60 Tank Size
Oil (RVP
5), Results
generated
from 4.0.9d
EPA Tanks
4.0.9d Software
215 dia. x 60 Tank Size

Sa

801
Nis
T9E

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While
floati
will h
and
differ
const
syste

82

Chart B is a sample VOC emission

the floating roof.

These drainage

Both
prove