FLOATING ROOFS
TA N K S T O R A G E June 2011
Attention to detail is certainly not a new concept but it often loses
emphasis in the bidding process as the focus tends to centre
around price
Its all in the detail
P
ontoon and skin type
aluminium internal
floating roofs (AIFRs)
are an evolutionary design
based on proven features
and lessons learned from
the observation and
repair of AIFRs and AIFR
manufacturers roofs that have
failed in the field of operation.
Most failures are caused
by inadequate floatation,
weak/poorly designed and
improperly assembled
components, structural
members spaced across
a large grid, poor test
port design and the use
of plated fasteners.
By conducting numerous
inspections, the design
of the AIFR has been
improved to increase the
products service life.
Often the design
improvements negate an
insidious flaw and are certainly
not an apparent subject in
the bidding process. Closely
examining the details are
necessary to distinguish
reliability and life expectancy
between a quality AIFR and
a low cost aluminum roof.
Design - manufacturing and field
installation
A quality AIFR is custom
designed from engineered
drawings for each unit built.
The roof is fabricated in the
shop, a controlled atmosphere,
using custom extrusions and
shapes, under strict controls,
demanding quality control
and standardisation, and then
field assembled by qualified
installers. The lower priced
AIFR is fabricated in the field
using standard sizes, shapes
and materials dependant on
varying field crew decisions,
technique and improvisation.
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Experienced field crews then
assemble AIFRs that are pre-
cut, pre-drilled and labelled.
This will produce a consistent
and quality product. AIFRs
that are field erected, often
with company supervision
using local unskilled labour
will produce an inconsistent
and varying quality product.
Inadequate floatation and
the inappropriate positioning
of pontoons have caused
failures. There are guidelines
in API 650 Appendix H, which
are the universally accepted
industry standards for
floating roofs. Under: H.4.2
internal floating roof design,
buoyancy requirements
are elucidated in detail.
H.4.2.1.2 calls for buoyancy
to support at least twice
the dead weight of the AIFR
and all components and the
calculated friction exerted by
peripheral and penetration Cable suspended roof
seals. What is not addressed
here is the positioning of and outlast bent sheet perpendicularly to the beams
the buoyancy (pontoons) pressed to the tank wall and attached to the perimeter,
especially on a large diameter to approximate a circle as produces a rigid and reliable
roof considering the friction provided in a low cost roof. AIFR. This becomes more
of a primary and secondary Examples of frequent prominent as tank diameter
seal. Failures can and have failures as a result of increases where more rigidity
occurred because there improperly assembled becomes necessary.
were not enough pontoons components are the The exclusion of pontoons
positioned at the perimeter. attachment of beams and as a structural component or
H.4.2.1.3 states that the pontoons and the mating of to use a flexible connection
AIFR shall be capable of beams and clamps to secure to join pontoons has been
floating if any two pontoons the skin. The basic structure advocated by some to
are punctured and flooded. If of a skin and pontoon AIFR mitigate the problem of
in doubt about the adequacy is a grid of perpendicular pontoon end cap failure.
of floatation for an AFIR being beams and pontoons. There End cap failure was a
presented, ask the supplier are contemporary designs chronic problem of one
for his calculations. A quality that decry the pontoon as of the most prolific AIFR
manufacturer will willingly a structural component, manufactures of yesteryear,
produce these calculations. but the pontoon, a tube, namely Mayflower, no longer
An example of the difference is an inherently strong in business. In designs where
in components starts with the structural component. The pontoons are a structural
AIFR perimeter. A specifically tubular profile has excellent component the pontoons
engineered and designed properties to withstand are fastened together and
extruded perimeter rolled to the forces of compression, incorporate leg sleeve
the exact circumference of torsion and bending in all connections or preferably
each tank will far outperform directions and when secured extrusions. Mayflower and
June 2011 TA N K S T O R A G E FLOATING ROOFS
other early designs had
weak end cap structures and
would fail due to the stresses
incurred from repeated
roof landings. Although
roof landings occur less
frequently because they are
an environmental issue, they
are no longer an end cap issue
for those that dramatically
improved end cap design.
The fix for this problem was
to design and incorporate rigid
structural weldments of the
end cap that make the end
cap stronger than the pontoon
itself and fasten the pontoons
together securely as an
integral structural component.
This method will outperform
non-structural or flexible joints
without welded gussets.
Beam and clamp mating
is the method of securing
the skin to the floating
structure. In this process
failures can result from poorly
designed and improperly
assembled components.
Inspections have often
revealed clamps not aligned
or not tightly mated to the
beams thus not properly
Interior end cap
Beam clamp joint
Underside of a cable suspended pontoon roof
securing the sheeting.
The method of extruded
component fabrication and
the fasteners used will make
a difference. The preferred
method is to shop pre-punch
the holes in both the clamp
and beam and to punch a
larger hole in the clamp, the
top component, and to fasten
and secure the skin with a self
tapping screw. This method
insures that the clamp, with
the skin in between, will be
pulled tightly to the beam.
The low cost method is to use
self drilling tek screws with no
shop pre-drilling. This method
can produce misalignments of
the clamp and beam and loose
skin joints. By not pre-drilling
a hole larger than the screw
shaft in the clamp; often the
beam and clamp will push
away from each other, rather
than pull together tightly.
Structural member spacing
is a major determining factor
Pontoon-type aluminium internal floating roof
in overall strength and rigidity.
API 650 Appendix H.4.2.1.4
calls for internal floating
roofs to support an applied
load of 500lbf over 1ft2
anywhere on the roof which
address two men walking.
Suppliers should provide
proof of compliance with
H4.2.3.1 which calls for
aluminum load carrying
members, assemblies and
connections to meet the
design requirements of
the latest edition of the
Aluminum Design Manual.
Poorly designed test ports
were a cause of pontoon
failure by allowing hazardous
liquid or vapours to enter
the pontoon. Test Ports in
pontoons started out as rivets,
evolved to gasketed sheet
metal screws, then to welded
couplings receiving threaded
pipe plugs, a prolific method
currently being produced
today. The problem with this
latest method is that the plug
is easily and often over-
torqued, cracking the coupling.
A better method is to weld
an aluminum nut inside the
end cap, than use a threaded
stainless sealing bolt with a
Teflon or nyseal gasket as
a test port. This allows the
tightest seal possible even
with repeated removals and
re-tightening without the
threat of damage or cracking.
Cadmium plated and
galvanised fasteners are
commonly used in low
cost aluminum roofs. The
resultant galvanic corrosion
from joining unlike metals
can drastically shorten AIFR
life. The recommendation
is that an AIFR purchaser
insist that only stainless
and aluminum fasteners
be used as addressed in
the recommendations in
API 650 H.4.3.3.1.
Price is not everything
The service life of a pontoon
type aluminum internal
floating roof is determined
by the details of design,
fabrication and installation.
Often a terminal may achieve
a lower price in the bidding
process, but it often comes
at the cost of a less-efficient
product and installation. n
For more information:
This article was written by Bill Grimes,
a sales engineer for Allentech,
www.allentech.com,
www.aluminumfloatingroofs.com
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