Tank Construction: Hydrotec Cs Guide

HydroTec CS TM
TANK
CONSTRUCTION
GUIDE
Trico Bond EP®

Table of Contents
Introduction 1-1 Fall Protection - Standard Operating

Purpose . . . . . . . . . . . . . . . . 1-1 Procedures 4-1
General Knowledge . . . . . . . . . . 1-1 General . . . . . . . . . . . . . . . . 4-1
Drawings . . . . . . . . . . . . . . . 1-1 Fall Protection System . . . . . . . . 4-1
Unloading Materials . . . . . . . . . 1-2 Fall Protection Components . . . . . 4-3

Installation and Use of Fall
Safety and Accident Prevention 2-1 Protection System . . . . . . . . . . 4-7
Builder Safety Guidelines . . . . . . . 2-1
Foundations and Site Preparation 5-1
Personal Protective
Equipment (PPE) . . . . . . . . . . 2-1 General . . . . . . . . . . . . . . . . 5-1
Wind Speed Awareness During Foundation Types . . . . . . . . . . . 5-1

Construction . . . . . . . . . . . . . 2-3 Foundation Tolerances . . . . . . . . 5-3
Hardware . . . . . . . . . . . . . . . 2-3 Major Centerline Orientation . . . . . 5-4
Crane Safety . . . . . . . . . . . . . 2-4 Base-Setting Ring Installation . . . . 5-4
Tools and Equipment 3-1 Tank Components and

General . . . . . . . . . . . . . . . . 3-1 Building Materials 6-1
Suggested Tools and Equipment . . . 3-1 General . . . . . . . . . . . . . . . . 6-1
Building Materials . . . . . . . . . . . 6-2
Bolts . . . . . . . . . . . . . . . . . . 6-4
Nuts and Washers . . . . . . . . . . 6-6
Bolt Tightening and
Torque Specifications . . . . . . . . 6-6
A325 Structural Hardware . . . . . . 6-8
1
Bottom Assembly and Installation 7-1 Hydrostatic Test Procedure 12-1
General Information . . . . . . . . . 7-1 General . . . . . . . . . . . . . . . 12-1
Bottom Construction . . . . . . . . . 7-2 Fill Tank and Inspect . . . . . . . . 12-2
Tank Assembly and Installation 8-1 Repair Procedure . . . . . . . . . . 12-2
Sidewall Construction . . . . . . . . . 8-1 Operation and Maintenance 13-1

Deck Assembly and Installation 9-1 General . . . . . . . . . . . . . . . 13-1
Deck Construction . . . . . . . . . . 9-1 Monthly Inspections . . . . . . . . . 13-1
General Installation . . . . . . . . . . 9-2 Annual Inspections . . . . . . . . . 13-2
Specific Installation Details . . . . . . 9-3 Periodic Internal Inspections . . . . 13-3
Completion . . . . . . . . . . . . . 9-10 General . . . . . . . . . . . . . . . 13-4
Miscellaneous 10-1 Appendix 14-1

Field Locating Nozzles . . . . . . . 10-1 Appendix A - Trico-bond EP
Touch-up Procedure . . . . . . . . 14-2
Coating Touch-up . . . . . . . . . . 10-2
Appendix B - HP Urethane Topcoat
Welding . . . . . . . . . . . . . . . 10-3 Touch-up Procedure . . . . . . . . 14-4
Appurtenance Installation 11-1

Flush Cleanout Assembly . . . . . 11-1
Shell Manway . . . . . . . . . . . . 11-2
Nozzle with Backing Flange . . . . 11-3
Overflow . . . . . . . . . . . . . . 11-4
Liquid Level Indicator Assembly . . 11-5
2
C H A P T E R
INTRODUCTION
CHAPTER1
Purpose
This manual provides a general outline of the construction tools,
methods, and sequences of erecting a Hydrotec™ CS (“chimed”) storage
tank. There are many variations and components that are customized for
each tank and are not covered herein.
Review all CST supplied drawings and this manual in it’s entirety before
beginning any installation.
If you are unsure of the requirements for building your tank, contact a
CST Field Service representative for specific guidance. CST
recommends the use of an experienced technical advisor for all tank
installations to assist those who are not experienced tank builders.
General Knowledge
It is assumed that the builder is knowledgeable in general construction
methods and terminology and has an existing safety program and manual
which applies to this and their other field construction efforts.
Drawings
A complete set of construction drawings is prepared for each tank order.
Copies of the drawings are forwarded to the customer. A typical set of
drawings would include the following.
1-1
Elevation and Bill of Materials Print
This is the key drawing in the set. It contains the bill of material listing all
parts and part numbers, accessories, and ring orientation.
Tank Detail Print

This drawing shows miscellaneous details, fastener and gasket schedule
indicating which fasteners and gaskets should be used in various
locations. Follow this schedule closely to ensure that the correct fasteners
are used.
Note: Failure to use the correct fasteners could result in disassembling and
rebuilding the tank at constructor’s cost.
Tank Stretch-out Print

This drawing shows the orientation of various tank components and
accessories.
Various Miscellaneous Drawings

Where required, these drawings will be sent showing assembly and
installation details for particular accessories furnished with the tank.
Unloading Materials
CST's materials are shipped by trucks or by container. A forklift or a
crane capable of lifting 6000 pounds will be required to unload materials.
If shipped by container, transportation from docks may be necessary.
All tank staves are shipped in special racks designed to protect the parts.
The shop applied coating is very durable, but is subject to damage if
mishandled or abused. Use extreme care to protect coating at all times
during unloading and construction.
Do not lift from end rack angles or from the bottom of the staves with the
forks of the forklift. This may result in damage to staves. Use the
following method to unload the stave racks.
CST Preferred Unloading Method

Use a spreader bar rated for a minimum of 7300 pounds to lift the stave
racks. Attach the spreader bar to the stave rack in at least four locations
by using properly rated hoisting straps or chains. Take care not to
damage the panel coating.
1-2 HydroTec CS Tank Construction Manual

Attach the chains or hoisting straps near the four corners of the stave rack
to evenly distribute the load and provide stability when lifting. Each
strap/chain must be rated for a minimum of 1825 pounds.
Note: If using chains, ensure there is no chance the chain can slip, come lose,
or shift. CST recommends attaching chains near the edge of the top angle
(second to last hole) by using the existing holes and running an SAE ½
inch Grade 5 bolt or equivalent through a chain link and the top angle.
Secure the chain link to the top angle using a ½ inch washer on both sides
and a grade 5 nut. Verify that the chain link and washer size are
compatible so that the link cannot slip around the washer and break free.
Storage
Carefully plan ahead for storage of materials. If possible, all materials

should be unloaded near the foundation and stored to eliminate any
moisture from contacting the coated surface.
Parts bolted or banded together for shipping must be separated with
spacers to prevent moisture from accumulating between parts. Elevate
deck and bottom sheets on one side so water can drain off. For long term
storage, parts should be stored inside or protected from the elements.
All paint and sealant should be stored in a dry area in a temperature range
of 55°F - 75°F.
To prevent pilferage and possible weather damage, store all boxes
containing hardware and small parts inside, or carry to and from job site
by the crew. CST cannot be responsible for theft of materials from job
site or items damaged due to weather exposure.
Inventories and Inspection

While unloading materials, careful inspection of each component should
be made; the consignee on the carrier's Bill of Lading should note any
damages to parts, or to coatings on parts. Part numbers and location of
damage should be added in the description of the part. Inventory of each
item should also be taken at this time, and any losses or shortages are to
be noted on Bill of Lading. Each shipment is carefully checked at the
factory. Any shortages or damages should be reported immediately and
photographically documented.
To aid in determining whether there is a shortage or loss, and to help
avoid costly delays, always check material received against packing list
1-3
or bill of materials sent with the load as well as against the bill of
materials listed on each drawing.
Note: This shipment has been carefully checked and packed. Upon arrival,
please list any visible damage or shortage on carrier's delivery orders.
CST is not responsible for parts lost or damaged in transit. Consignee
must notify CST of any shipping discrepancies immediately upon
delivery.
Any discrepancies not reported to CST Project Management within seven

days of delivery will be handled entirely at consignee's expense.
Contact CST project management for all communications after shipping.
CST is not responsible for any charges or expenses due to delays,
shortages, errors in shipment, or incorrect fabrication of parts.
CST MUST approve any field rework of parts, and/or back charges, in
advance.

C H A P T E R
SAFETY AND ACCIDENT PREVENTION

CHAPTER2
Builder Safety Guidelines

A general rule of good management is to be safety conscious. The
installer should read this manual and understand the entire process before
beginning construction.
There are certain federal, state, and local regulations which require the
wearing of protective apparel and use of safety equipment. All installers
should develop and implement a safety program, and adhere to all
federal, state, and local guidelines and regulations.
Personal Protective Equipment (PPE)

Personal Protective Equipment (PPE) should be used at all times. Its use
should be covered by the installer’s safety program.
2-1
Minimum Suggested PPE Requirements
1 Ear Plugs 4 Hard Hat

2 Safety Glasses 5 Work Gloves
3 Fall Protection Harness & 6 Steel Toed Non-slip Safety
Lanyard1 Shoes
1.For detailed information see Chapter 4, “Fall Protection - Standard Operat-
ing Procedures”.
1 2
3 4 5
Figure 2.1

Wind Speed Awareness During Construction
While under construction, the tank is NOT capable of withstanding
heavy sustained winds or large wind gusts. It is the construction crew's
responsibility to secure the tank during construction.
Securing the tank
WARNING:
Tank cannot withstand heavy sustained winds or
wind gusts during construction. Failure to heed
could result in serious personal injury or death.
A partially erected tank must be tied off at each vertical seam if excessive
winds are imminent.
Do not start a new ring if weather is questionable. Always start a new
ring with the intent to finish before inclement weather approaches or the
end of the day. Tie off recommendations are for completed rings only.
Hardware
WARNING:
Use CST Storage supplied hardware. Failure to
heed could result in catastrophic tank failure.
CST Storage tank hardware is specifically designed to handle the

structural and corrosion requirements for a particular tank configuration
and application. Randomly replacing or substituting non-CST approved
hardware can cause a catastrophic tank failure. See Chapter 6, “General
Assembly Information” for more hardware information.
2-3
Crane Safety
WARNING:
Use proper lifting and rigging as appropriate.
Failure to heed could result in serious personal
injury or death.
When cranes are used, the user is responsible for determining the weight
and developing a rigging and lift plan as appropriate.

C H A P T E R
TOOLS AND EQUIPMENT

CHAPTER3
General
The following includes the recommended tools and equipment typically
required to construct the HydroTec CS storage tank.
The user is responsible for determining the weight and developing
rigging and a lift plan as appropriate.
Suggested Tools and Equipment

The following is a list of recommended standard tools and equipment.
Description Description
18 inch crescent Caution tape
12' x 5/8" steel choker ½ inch ratchet
10' x 5/8" steel choker Vise grips of assorted size
8' x 5/8" steel choker 2 inch ratchet straps
4' x 5/8" steel choker Bucket, 5 gallon
¾ inch shackle Spring link (ring to attach wrench to harness)
Dewalt electric impact ½ inch Orange flagging tapes
½ hp electric drill 3 inch snatch blocks (type 419)
4-½ inch grinder ½ inch shackles
Electric Dremel tool and bits (For coat- 3/8 inch shackles
ing touch-up repairs)
Transit level kit (transit stand, level, Ingersoll Rand IR-231 Impacts (air - ½ inch
stick) pneumatic)
3-1
Description Description
3 pound mini sledge 3/8 inch air drill
4 pound hammer 11 PC impact socket set
Nylon tool pouch belts 17 PC wrench combo set
Bolstice 36 inch wrecking bar 12 foot nylon straps
16 oz ball peen hammers 50 foot ¾ inch air line
Dead blow hammer 28 oz 50 foot ½ inch air line
Cold chisels 7/8 inch Klein bolt buckets 5109
3 pound hammer Screw driver set
2 inch hole saw 4 foot level
½ inch steel drill bits Combo channel locks (2 pack)
16 oz claw hammers Crescent wrenches, 12 inch
1-½ inch hole saw Klein tool pouch belts
Wonder bar Bull pins
Caulking guns Level, 2 foot
3/8 inch steel drill bits Needle nose pliers
9 inch torpedo level ¾ inch wrench
Cut off wheels, 4 inch 11 inch C-Clamps with sheeps feet
Razor knifes Klein bolt bags
Grinding wheel, 4 inch 25 foot tape measures
Air oiler Framing square
Impact whips 9/16 inch wrench
Air hose safety cables checks ¾ inch impact socket deep
Crows foot, ¾ inch 9/16 inch impact socket deep
Crows foot, ½ inch Plumb bob
¾ inch air gromlets Chalk line
Safety pin air Speed square
Sawsall Pipe wrench, 24 inch
Step ladder, 8 foot ¾ inch sheet plywood
Step ladder, 6 foot 3/8 x 2-½ inch bolts, nuts, washers
Extension ladder, 24 foot Line up bars
Electrical cords (12 GA), 100 foot Reamers
12 ton bottle jack Drill bit kit
GFCI Wrenching bar, 36 inch
Steel tape, 100 foot

The following is a list of recommended specialty tank installation
equipment that is commonly used to install a tank. The quantities may
vary depending upon the size of the tank. This equipment is available for
purchase from Daystar Safety at 800-747-1401. Consult Daystar Safety
to determine exact quantities required.
Description Quantity
Scaffold Bracket 1 per stave
Scaffold Planks1 2 per bracket
for 1 ring
Drive-out Ladder, Nut-up Ladder One each
Gin Pole One
Pneumatic Air Tugger or Crane One
Handrail Post and Guardrail System 1 per bracket
for 1 ring
Horizontal Lifeline System 2 minimum,
max. deter-
mined by tank
diameter
Skyhooks 6
1.Scaffold planks must be high grade lumber, stress-graded at 2,000 pounds
or better. Must conform to OSHA standards.
Ladders
There are typically two types of speciality ladders used for tank assembly
that hang from the top of an installed ring. The first ladder (drive-out
ladder) is approximately 12 feet long and used to access the interior of
the tank to drive-out the sidewall bolts after the sheets have been
installed. The second ladder (nut-up ladder) is approximately seven feet
long and is used on the exterior of the tank to access the top of the ring
for installing the nuts or other work as required.
3-3
NUT-UP LADDER
DRIVE-OUT LADDER
Figure 3.1

Gin pole and Tugger
The gin pole and tugger system is used to lift the sheets up to the higher
elevations as the tank is being assembled. The preferred tugger is an
Ingersoll-Rand IR-D6U loaded with 365 feet of ¼ inch wire rope, 7 x 19
GAC.
During tank assembly, the cable is routed up to the gin pole located near
the top of the tank through the pulley and back down to grade to connect
the stave. The gin pole is two piece and is manually positioned from the
scaffolding and is moved around the tank as each sheet is lifted.
GIN POLE
Figure 3.2
3-5
Notes:

C H A P T E R
FALL PROTECTION - STANDARD

CHAPTER4
OPERATING PROCEDURES
General
The scaffold system and all tank-specific installation equipment is not
part of the tank and may be purchased separately from Daystar
Corporation at 800-747-1401.
This is an engineered system and all components must be purchased from
Daystar Corporation and used in accordance with their recommendations.
They can provide a design package for all equipment that is approved and
stamped by a professional engineer.
Fall Protection System

A fall arrest system may be required if a worker could fall from an
elevated position.
A personal fall arrest system must be used anytime a worker is on a
walking or working surface (horizontal and vertical surface) with an
unprotected side or edge that is 6 feet (1.8 m) or more above a lower
level, unless protected from falling by the use of a guardrail system.
A fall arrest system will only come into service should a fall occur. A
full-body harness with a shock-absorbing lanyard or a self retractable
lifeline is the only recommended fall protection equipment. A full-body
harness distributes the forces throughout the body, and the shock-
absorbing lanyard and/or self retractable lifeline decreases the total fall
arresting forces on your body in case of a free fall.
4-1
Shock Absorbing Lanyard Fall Clearance Calculation With
Overhead Anchorage
6 ft
Length of Lanyard
(LL)
17 ½ ft
Required Fall
Clearance
Distance Using
Typical 6 ft
Lanyard (RD)
3 ½ ft
Deceleration
Distance (DD)
6 ft
Height of
Suspended
Worker (HH)
Nearest Obstruction
2 ft Safety Factor (C)
LL= Lanyard Length

DD = Energy absorber Deceleration Distance (3 ½ ft total)
HH = Height of Harness dorsal D-ring from worker’s feet
C = Clearance to obstruction during fall arrest (1 ft required plus 1 ft for
D-ring movement and system materials stretch = 2 ft total)
RD = Required Distance below anchor point to nearest obstruction
RD = LL + DD+ HH + C
Figure 4.3

Typical Fall Clearance Calculation
To determine the required fall clearance, add the appropriate factors to
determine the safe Required Distance (RD) below the working surface
for work which is to be carried out where there is any risk of falling.
When connecting the lanyard to a fixed overhead anchorage, a minimum
fall clearance of 18 feet from the anchor point to the lower level or
nearest obstruction is recommended.
Calculation based on free falls up to 6 feet and 310 pound personnel.
Shock Absorbing Lanyard Fall Clearance Calculation With

Anchorage At Feet
When connecting the shock absorbing lanyard to a fixed anchorage or

horizontal lifeline at your feet a minimum fall clearance of 21 feet is
recommended.
Self Retracting Lifeline Fall Clearance Calculation

The maximum arresting distance for a Self Retracting Lifeline (SRL) is
42 inches. When used correctly the SRL will limit a free fall to 2 feet or
less. When connecting the SRL to a fixed anchorage overhead, a
minimum fall clearance of 6 feet from the working level to the lower
level or nearest obstruction is recommended.
Fall Protection Components

The following components make up the fall protection system and must
be used as designed without any modifications unless approved by the
engineer or vendor.
All equipment should be inspected by a competent user before every use.
If any deformation or damage has occurred it should be tagged and taken
out of service.
Scaffold Bracket
The scaffold brackets should be spaced at a maximum of 5 feet on-center.
The scaffold bracket will be attached at the top on the sixth and seventh
bolts and at the bottom on the twentieth bolt of the vertical seam below
the chime. Both pieces of the scaffold bracket have a 7/8 inch hole that is 2
4-3
inches from the tank that can be used for a fall protection anchorage
point. Only one person can be anchored to a scaffold bracket for fall
protection. A maximum of two people are allowed to stand on the
scaffold boards between any two installed scaffold brackets.
The heavier (68 pound) scaffold bracket must be used when working
below 21 feet (measured at the feet of the worker). The lighter (28
pound) scaffold bracket can be used when working above 21 feet.
38 3/4"
28 15/16" (Heavy Bracket)

28 7/16" (Light Bracket)
Guardrail System
The guardrail system consists of the following:

1 Scaffold bracket with 6 inch rod
2 47 inch long handrail post
3 3/8 inch diameter 7x19 galvanized aircraft cable
4 Two turnbuckles
The guardrail post should be pushed all the way down over the smaller
connecting rod on the scaffold bracket. The cables should be inserted
through the top and middle holes located on the handrail posts and then
connected to the two turnbuckles. The turnbuckles should be tightened to
provide a minimum of 2-½ inch sag and a maximum of 3 inch sag under
a 200 pound down load force on each cable. The cable is connected to the
turnbuckles by use of three properly installed cable clamps.

The heavier guardrail post must be used when working below 21 feet.
The lighter guardrail post can be used when working above 21 feet.
GALVANIZED
HANDRAIL AIRCRAFT
POST CABLE
SCAFFOLD
BRACKET
SCAFFOLD
BOARD
Figure 4.4
Horizontal Lifeline System

The horizontal lifeline (HLL) system consists of the following:
1 Nominal ½ inch diameter x 60 feet long 6 x 19 galvanized wire rope
with eyelet thimbles on each end
2 One turnbuckle
3 Two carabineers
4 Six shackles/bolts/lock nuts
5 Two Zorbit energy absorbers
6 Two anchor angle brackets (each with two 2 inch and 2-½ inch bolts
depending on tank thickness)
7 Five interior angle brackets.
4-5
The seven angle brackets will be bolted on vertical seam holes below the
chime but above the scaffold bracket. The beginning and ending anchor
angle brackets will be spaced at a maximum of 60 feet. The interior angle
brackets will spaced equally between the anchor brackets and at a
maximum of 10 feet on-center. The cable will have a Zorbit energy
absorber and turnbuckle attached at one end for tension adjustment which
will be attached to the anchor bracket with a carabineer. The remainder
of the cable will be placed through the hole in the five interior brackets
and another Zorbit will be attached to the eye of the other end of the cable
and attached to the last anchor bracket with a carabineer. The turnbuckle
will then be adjusted to make the cable deflection at mid span to be 6
inches or less with no weight on the cable and the cable is secured by use
of three properly installed cable clamps.
A maximum of two workers can be attached to any one 60 foot section of
the horizontal lifeline at any given time. There must be a fall clearance of
at least 21 feet when attached to the horizontal lifeline at your feet when
using a lanyard, or a fall-restraint lanyard along with heavier bracket
components, must be used.
Harness and Lanyards
Only harnesses and Force 2 shock-absorbing lanyards by DBI-Sala are

allowed to be used as fall protection when connected to the horizontal
lifeline. When the employee is working at a height above 21 feet
(measured at their feet), they can use the shock-absorbing lanyards.
When a worker is working at a height under 21 feet (measured at their
feet) and has a guardrail system behind them but does not have tank
staves in front of them - generally only the two employees hanging the
staves - they must also use a fall restraint/positioning lanyard that is of
the proper length which is attached to the top guardrail cable and the D-
ring on the back their harness that restricts their forward movement so
they cannot fall into the tank.
Sky Hook
The sky hook is designed to be placed over the top of the panel and used
as an anchor point for fall protection for one worker. It should be
positioned directly overhead and as far away from the open edge of the
panel as possible, but no closer than 5 feet. A lanyard or self retracting

lifeline may be connected to the anchorage point on the sky hook for fall
protection.
SKY HOOK
Figure 4.5
Fall Protection Rescue
In the event that a worker falls and is suspended by their self retracting
lifeline or lanyard a fall protection rescue plan will be implemented. The
R500 rescue and descent device should be attached to a fall protection
anchorage point (scaffold bracket or sky hook) above the fallen worker
with a carabineer or sling. The snaphook on the R500 should be attached
to the D-ring on the back of the harness of the fallen worker or to an
inverted rope grab attached to the fallen worker's lanyard. The rescue hub
can then be used to slightly raise the fallen worker in order to disengage
the self retracting lifeline or lanyard, so the R500 descender can lower
the worker to the ground at an automatic controlled descent of 2-3 feet
per second. Each crew should carry one R500 descent, be trained on its
use, and have it available for use.
Installation and Use of Fall Protection System

This system is designed to be used with a chimed tank that is
manufactured by CST Storage and should only be used under the
direction of a competent person and by individuals who have been
trained on its use, and should be used in conjunction with the Tank
Installation Manual and Drawings from the manufacturer.
4-7
The scaffolding system is installed after each ring of the tank is built to
provide a stable working surface for installation of the next ring. Prior to
installation and use of the scaffolding, each ring of staves to which it is
attached should have all hardware installed and tightened per
manufacturer's recommendation.
1 Begin by installing one scaffold bracket on each vertical seam of the
tank. During installation of the brackets overhead, each worker should
always be connected to at least one of the following: the horizontal
lifeline below, the hole in the scaffold bracket angles, or to a sky hook,
depending on availability of an anchor point during the process and the
position of the worker completing the task.
2 Once all brackets have been installed on the vertical seams of the next
ring of staves, the OSHA-approved scaffold boards are passed up and
placed on the scaffolding. The boards should be centered on the two
supporting brackets and overlapped with subsequent boards by at least
12 inches. The platform should be two boards wide.
3 As the boards are placed around the tank, the horizontal lifeline and
guardrail system are passed up and installed.
4 When installing the anchor angle brackets at each end of the HLL, it
will be necessary to use longer bolts than those provided with the tank
because of the thickness of the anchor bracket. If the stave ring being
installed is 3/16 inch thickness or less, than the anchor angle bracket
bolts will need to be 2 inches long. If the stave ring is greater than 3/16
inch thickness, than the anchor angle bracket bolts will need to be 2.5
inches long. All interior angle brackets should work adequately with
standard tank bolts as long as a full nut fits on the bolt.
5 Once the entire HLL and guardrail systems have been installed, they
should be properly tensioned and inspected.
6 Repeat the process for each subsequent ring.
The horizontal lifeline cannot be used as an anchor point until all seven
angle brackets are installed and the cable is properly tensioned.
While installing the staves at the leading edge of the ring, the two
hangers must be connected to the top guardrail cable with a properly
adjusted fall restraint/positioning lanyard when the height of their feet is
21 feet or less (refer to “Harness and Lanyards” on page 4-6). They
should also be simultaneously connected to the horizontal lifeline by
their shock-absorbing lanyards. The sky hook should primarily be used
by the individuals who are working on the driveout ladder, who are

installing and tightening nuts, or anyone else who is doing work on the
scaffold system and is not connected to the horizontal lifeline.
Removal of the scaffolding is done in reverse order. At all times the
employees involved in removing the scaffolding should be connected to
the horizontal lifeline (if complete and properly tensioned), to one of the
scaffold brackets, or to a sky hook. All workers working on the
scaffolding must maintain 100% tie-off to a component of the fall
protection system.
4-9
Notes:

C H A P T E R
FOUNDATIONS AND SITE PREPARATION

CHAPTER5
General
There are several types of foundation designs available for supporting the
tank. Foundation design specifications are the responsibility of the
customer or their engineer. CST recommends that all foundation designs
be completed by a local engineer familiar with the local codes and
conditions of the specific area of construction and in accordance with the
latest edition of AWWA-D103.
The type of foundation and how the tank is anchored is dependent upon
the application, allowable soil bearing pressure, environmental factors
like wind and seismic load, and the foundation loads from the tank. CST
recommends the site soil investigation be prepared and stamped by a
licensed geotechnical engineer to assure adequate soil bearing capacity is
available.
Foundation Types
There are four common types of foundations that can be used depending
on the design requirements and engineer's discretion.
Grade Band
A grade band is a steel band that is used to contain a suitable backfill
material like sand or pea gravel for an unanchored tank. The grade band
is typically one to one-and-one-half feet larger in radius than the diameter
of the tank and may be embedded in the soil. The grade band and fill
5-1
shall be level within ±¼ inch. The grade band is anchored in place with
stakes and backfilled, but the tank is un-anchored.
Ringwall
A ringwall is a concrete ring that is partially buried in the soil. The

interior of the ringwall is filled with a suitable backfill material. A small
concrete base may be required in the center of the ringwall to support the
tank center pole (if required). The tank on a ringwall may be anchored or
un-anchored. An asphalt-impregnated fiberboard and/or plastic sheeting
material may be placed on top of the ringwall/backfill and under the tank.
Full Slab
A full slab concrete foundation provides 100% support under the base of
the tank and can be either anchored or unanchored. An asphalt-
impregnated fiberboard and/or plastic sheeting material may be placed on
top of the ringwall/backfill and under the tank.
Base-setting Ring
A base setting ring foundation is when a partial ring of the tank sidewall
is embedded in the concrete slab. The first pour is the footing with
embedded anchors and brackets. The base ring is then installed on the
brackets prior to placement of the second pour which is a continuous
monolithic pour around the base ring. The entire interior floor of the tank
is concrete. See the section on installing base setting rings for additional
information.
Anchoring
When anchor bolts are required by design, they can be installed in place
before the concrete is poured or by installing epoxy-type anchors after
the concrete has been poured. The size of anchors and the embedment
depth can be found on the tank drawing if the anchors are provided by
CST.

Foundation Tolerances
All foundations or anchors installed by the customer must meet the
following levelness tolerances to ensure that the tank can be assembled
properly. Survey or other measurement data must be provided to CST.
If it is determined that the specified tolerances have been exceeded and
are not corrected, and the installation proceeds, fit-up may be difficult
and there may be denting, buckling or other distortion in the shell or
other parts of the tank. The deformation may be cosmetic, but CST is not
responsible for correcting them to an undistorted state and any CST
warranty is considered voided.
Grade Bands for Liquid Tanks
Grade bands and the backfill shall be level within ±¼ inch.
Slabs and Ringwalls
All slab and ringwall foundations shall meet the levelness tolerances and
other requirements of AWWA and/or ACI. Unless otherwise stated,
foundations shall be level within ±1/8 inch in any 30-foot circumference
under the shell. The levelness on the circumference shall not vary by
more than ±¼ inch from an established plane.
Base Setting Rings
The base setting ring staves shall meet the following tolerances before
and after the final concrete pour. The levelness on the circumference at
the top of the staves shall not vary by more than ±1/16 inch from an
established plane. The radius of the staves to the center of the stave shall
be within ±1/8 inch from the center point of the tank. The staves shall be
plumb to the vertical within ±1/16 inch.
Anchor Bolts
Anchor bolts installed by the customer shall be oriented as shown on the

CST engineering drawings. An anchor bolt template may be purchased
from CST.
Anchor bolts shall be plumb to the vertical within 3 degrees and the
projection above the top of concrete within ± ¼ inch. The radial position
5-3
with respect to the center point of the tank shall be within +¼ inch and -0
inches. The chord between anchor bolts shall be within ±1/8 inch and is
non-accumulative between successive anchor bolts. Anchor bolts cannot
be bent or otherwise distorted to fit within the anchor chair on the tank.
Major Centerline Orientation

The major centerlines shall be laid out on the foundation by the customer
to identify the zero degree orientation and 90, 180, and 270 degree
centerlines of the tank nozzles with respect to the piping connection
points of the facility. The centerlines shall be within ±¼".
Base-Setting Ring Installation

A base-setting ring installation is when a bottom partial ring of the tank is
embedded in concrete and the floor is concrete, not steel. The concrete is
typically placed in two pours – the footing and the floor.
1 Before the footing concrete is placed, pre-assemble the two anchor
bolts and the leveling angle as shown in Figure 5.1.
Figure 5.1
2 Place the footing concrete.
Note: It is critical that the anchor/leveling plate assemblies be placed accurately
into the footing concrete.

3 Insert the staves support angle assemblies into the fresh concrete
located as shown on the drawing relative to the zero degree
orientation.
Figure 5.2
4 Position assemblies such that the tape measure passes directly over
both anchor bolts when extended from center of structure as shown to
ensure radial alignment. The radius of the tank should be measured
from the center of the tank to the center of the leveling angle.
TAPE MEASURE
CENTER OF TANK
Figure 5.3
5 After the footing concrete has hardened, level each stave support angle
assembly before installing the foundation sheets. Level each
anchor/leveling plate assembly around the footing to within ±1/16 inch
by adjusting the nuts on the anchor bolts as required. Check for level
by placing a torpedo level along the length of the plate. Check the
height by placing a transit rod on top of the plate. Securely tighten nuts
on anchor bolts when all adjustments have been made.
5-5
Foundation Sheet Installation
1 Prepare the base setting ring panels by pre-installing the specified

gasket and hardware as shown on the construction drawings.
2 On each leveling assembly mark the radius of the tank that
corresponds to the outside of the chime to set the location of the panels
on the leveling assembly.
3 Set the base setting ring sheets onto the leveling plate assemblies. Each
sheet should be located on the anchor assemblies as shown in the
drawing. It is important that the first sheet layout is correct relative to
the zero degree orientation shown on the drawing.
4 The nuts on the vertical seams should only be loosely snugged up
against the sheets during the assembly.
Once the entire base setting ring is in place on the leveling assembly, it is
very important to go back and verify the radius and height of each panel
to confirm they meet the tolerances specified on the drawing.
1 Take radius measurements from the center post to each sheet, above
the leveling plates and at the center point of each panel (halfway
between successive vertical seams). Consistency in where the
measurements are taken is important. The measuring tape must be
level. The tolerance on the radius is ±1/8 inch.
2 Use C-clamps or vice grips to secure the sheets to the stave support
angle assembly once the proper dimension is achieved.
3 Install all anchor J-bolts as indicated on the drawing in the vertical
seams.
4 Tighten all bolts in the vertical seams as described in this installation
manual.
Note: All bolts must be adequately tightened to ensure compression of the
gasket prior to placement of the concrete or the foundation will leak at all
seams.
5 Check that the foundation sheets are level using a transit and target
rod. Take readings from the top of the chime. Adjust leveling plate
heights to achieve proper height and level throughout the foundation
ring. The tolerance is ±1/16 inch. When additional height adjustment is
not necessary, tighten the foundation bolt nuts.

6 Recheck concentricity and levelness of the foundation ring assembly
all the way around the tank again. Once all measurements are within
tolerance, tack weld the bottom chime to the angle at each assembly. If
necessary, install bracing to the top chime to prevent the stave panel
from moving during placement of the steel or concrete.
7 Place all rebar and forms per the foundation design.
Foundation Seal Strip General

The foundation conseal sealer is used to form a liquid resistant seal
between the concrete floor and the foundation sheets. See Figure 5.4.
Note: The seal strips are to be applied just prior to placing the concrete.
Foundation Seal Strip Installation
The conseal is attached to the inside and outside surface of the base-
setting ring sheets as shown on the drawings and forms a continuous
sealing band. General installation procedures are as follows:
1 Clean the circumferential surface of the base-setting ring sheets where
the seal strips are to be applied.
2 The conseal shall be formed to fit tightly against the sheet edge at the
vertical seam and shall run continuously between bolts.
3 The Conseal strip shall be butt spliced, not overlapped.
4 Do not place the butt splice within 12 inches of a vertical seam.
5 Avoid stretching the seal strip.
Closed Cell Polyethylene

The closed cell polyethylene allows for expansion of the steel against the
concrete and shall be placed non-continuously between the vertical rows
of bolts of each sheet. The top of the polyurethane should be flush with
the top of the final concrete pour. See Figure 5.4.
Check the concentricity and levelness again before placing concrete to
ensure there has been no change or movement during other work.
Place the concrete for the rest of the floor and foundation in accordance
with final construction drawings.
5-7
Once the concrete has cured, apply the CIM material and bonding agent
as shown. See Figure 5.4. Refer to the Application Instructions for the
CIM materials that are available from their website at www.cimind.com.
CIM
CIM
CLOSED CELL
POLYETHYLENE
BONDING AGENT
CONSEAL
STAVE SUPPORT
ANGLE
FOUNDATION
BOLT
Figure 5.4

C H A P T E R
TANK COMPONENTS AND BUILDING

CHAPTER6
MATERIALS
General
All bolted steel CST tanks consist of prefabricated formed staves,
circular decks, and bottoms. A broad range of capacities is achieved by
varying heights and diameters. The following list of components is
typical of CST tanks. Familiarizing yourself with the terminology of each
item will aid in understanding the remainder of this manual and
identifying parts in the field.
Staves are bolted together at vertical seams to form stave rings. Each ring
is designed to support the load imposed by its contents plus loads
transferred to it from the rings above. Thus, stave thickness is increased
from thinnest in the top ring to thickest in the bottom ring of the tank.
The shell is formed by bolting stave rings together at the chime
(horizontal seam) to develop the required height. The bottom ring of shell
can be equipped with a flush cleanout or manway, which provides access
to the tank for easy cleaning. Plain rings complete the shell. Bolt-on
nozzles can be installed as required for filling and draining tank contents,
instrumentation, etc.
The bottom is joined together at radial seams to form a circular floor.
The center portion of the floor utilizes a center plate, and on larger
diameter tanks an adapter ring is also added. For a cone bottom, the
center plate may be replaced with a recessed sump.
6-1
Decks are formed similar to bottoms and are available in either self-
supporting or supported by a center support.
Best Practices
When installing the deck and bottom, loosely install all components and
fasteners before tightening.
All decks must be installed so that where the deck sheets overlap they
create a shingled effect to shed rainwater.
There should always be a gasket between steel at all exterior joints. There
should never be steel to steel contact.
All tanks over 20 feet tall shall be plumb at the top relative to the bottom
within 1/200th of the total height.
The roundness may be measured from the tank center to the center of the
stave (between vertical seams) at a height one foot above the bottom of
the tank and it shall be within ±¼ inch.
Building Materials
Some fasteners and gaskets listed here may or may not be used in a
particular application. The following are examples of typical gaskets and
fasteners that are used on HydroTec tanks. Always refer to the
construction drawings supplied with each tank for the exact usage and
placement on the tank.
All materials provided by CST are new materials in accordance with their
respective ANSI, ASTM, or other applicable standards. Material Test
Certification Reports are available from CST upon request.
The materials should be visually inspected prior to installation to confirm
that they are in adequate condition and suitable for use. If damage or mis-
fabrication is noted, it should be reported to CST for a determination on
its use or replacement.
Gaskets and Caulk
Gaskets are used at every bolted joint in the tank. No connection on the
tank should ever be metal-to-metal.
Strip Gaskets are used on the vertical and chime (horizontal) joints.
Strip gaskets are supplied in rolls and cut to length during the installation

process. In places where a splice is required, apply caulk and overlap the
gasket by two holes.
Strip gaskets come in single, double, and triple bolt row configurations.
Use the appropriate gasket to match the number of bolt rows in the joint.
Chime Lap Gaskets are used to fill the gap at joints where three
thicknesses of material come together (panels to panels or panels to floor
or deck joints). The bump side of the gasket goes into the void created by
the lapping panels. Apply a small amount of caulk to the bump and both
ends of the chime lap gasket during installation.
Light bump gaskets are used at 3/16 inch through 12 gauge chime laps.
Heavy bump gaskets are used at ¼ inch and 7/32 inch chime laps.
Heavy step gaskets are used on 5/16 inch chime laps, bottom chime when
stave thickness is 5/16 inch, and bottom seam to chime connection when
the bottom thickness is 3/16 inch or greater.
LIGHT BUMP HEAVY BUMP
HEAVY STEP
Figure 6.1
Radius Gaskets are used at the “corner” of a vertical joint. They are
installed between the panel and the strip gasket. Apply a small amount of
caulk to both sides of the radius gasket during installation.
6-3
Panels which are single punched require the 1-¾ inch long gasket. Panels
which are double punched require the 3-¾ inch long gasket. Panels which
are triple punched require the 5-¾ inch long gasket.
3-¾" 5-¾"
1-¾"
RADIUS GASKETS
Figure 6.2
Circular Gaskets are used for domes, collars, etc. and are supplied in
one piece or several pieces which are joined to form a ring.
Special caulk is supplied and used at specific locations where gaskets
alone are not sufficient to seal the tank. The caulk is shipped in
cartridges. A caulking gun is required for dispensing the caulk.
Bolts
Fin Neck Polycap Bolts - ½ inch diameter fin neck polycap galvanized
bolts of various lengths are used on all vertical seams, in the deck, and on
appurtenances. The bolts in the vertical joints are secured with ½ inch
neoprene backed steel washers and ½ inch hex nuts.
Depending upon the application they are supplied with or without plastic
encapsulation. These bolts should be installed with the bolt head on the
inside of the tank. These bolts are typically Grade 5 bolts, but may be
Grade 8 depending upon the design. Grade 5 bolts are gray in color from
galvanizing and Grade 8 bolts are gold in color and may be stamped with
the numeral “8” in the end of the bolt.

Square Head Bolts - ½ inch square head Grade 2 bolts are used in the
bottom and at all horizontal (chime) joints. These are secured with ½ inch
steel flat washers and ½ inch hex nuts.
FIN NECK POLYCAP BOLT SQUARE HEAD BOLT
Figure 6.3
Square Head Bolts and various Bolt Channels are supplied for use on
the bottom seams and are installed from under the floor.
BOLT CHANNEL WITH SQUARE HEAD BOLT
Figure 6.4
6-5
Nuts and Washers
½ Inch Hex Nuts are used on all stave and deck joints.
Encapsulated or TecCap nuts may be used on internal bottom bolts.
½" HEX NUT ½" ENCAPSULATED NUT ½" TECCAP NUT
Figure 6.5
½ Inch neoprene backed steel washers are used at each stave vertical
seam and may be used on bottom floor bolts.
½ Inch flat washers are placed under nuts on all chime and deck bolts.
NEOPRENE BACKED WASHER FLAT WASHER
Figure 6.6
Stainless steel hardware may be used in the deck structure, brackets, or as
otherwise specified on the installation drawings.
Bolt Tightening and Torque Specifications

For standard ½ inch bolts, various factors such as panel thickness, the
coating on the steel, type of fastener, and straightness of the steel affect
the amount of torque required to tighten a seam. As a result of the
numerous applications, CST does not specify a minimum or required
torque value for tightening the bolts. The information below will give
general information for erecting and tightening a bolted tank.

The proper seal is made when the bolt has been tightened enough to
compress the gasket until it moves in the joint between the steel.
Watching the gasket in the lap joint while tightening the bolt easily
verifies this. Experience with many grades and thicknesses of steel, along
with different types of gasket, hardware and coatings has proven that this
method of tightening will consistently ensure a leak-free joint. A set
torque may not always compress the gasket properly. Bolts that are too
tight will damage the gasket.
If a torque value is required, or if bolts in a multiple row seam are to be
checked, it is suggested that a torque wrench be used after the gasket has
been compressed. This will establish a reference point for that seam
which should be fairly representative for the entire ring. A variance of
25% is acceptable.
CST has determined that the following torque ranges generally provide
acceptable tightness of the joints for the tank to be leak-tight when it is
built in accordance with the requirements in this manual. Excessive
overtightening (>120 ft-lbs) may damage the gasket.
Fastener Grade Minimum Torque Joint Location
2 or 5 50-55 ft-lbs 10 & 12 gauge floor

thickness with hex nut
or encapsulated nuts
60-65 ft-lbs Lap bolts in floor
70-75 ft-lbs ¼ inch floor thickness

with hex nuts
75-80 ft-lbs Vertical seam sidewall

seams up to and
including 3/16 inch
90-95 ft-lbs Vertical seam sidewall

seams ¼ inch and
greater
70-75 ft-lbs All horizontal seams
50-55 ft-lbs All deck sheets
8 90-95 ft-lbs All joints
6-7
One-piece neoprene backed steel washers should be tightened until they
flatten. It is not uncommon to spin off part of the neoprene washer for a
proper seal. Their purpose is to seal the threads of a bolt. It is not
detrimental to the integrity of the tank if the excess neoprene comes
loose.
Plastic encapsulated bolts and encapsulated nuts should be tightened until
the raised ring on the bottom of the plastic cap is flattened. A visual
inspection may be done initially to ensure the ring is sealing against the
steel. Tighten a few fasteners first and check them before tightening all
fasteners.
All encapsulated nuts and bolts should be visually inspected for
mechanical damage. It there is any damage replace the damaged fastener.
A325 Structural Hardware

Unless noted otherwise on the CST drawing, all structural bolt
applications (non-gasketed) are designed as snug-tightened joints in
accordance with the Specification for Structural Joints using ASTM
A325 or A490 Bolts published by the Research Council on Structural
Connections. In accordance with this specification, the snug-tightened
condition "is the tightness that is attained with a few impacts of an impact
wrench or the full effort of an ironworker using an ordinary spud wrench
to bring the connected plies into firm contact".
More than one cycle through the bolt pattern may be required to achieve
the snug-tightened joint condition. The nut and protruding end of the bolt
should be match-marked prior to pre-tensioning to aid inspection. The
assembly should be pre-tensioned using the turn-of-the-nut method. If
the bolt length is not more than four times the bolt diameter, the nut
rotation should be 1/3 turn beyond snug tight. If the bolt length is four to
eight times the bolt diameter, the nut rotation should be 1/2 turn beyond
snug-tight. The part not turned by the wrench shall be prevented from
rotating during this operation.

C H A P T E R
BOTTOM ASSEMBLY AND INSTALLATION

CHAPTER7
General Information
Prior to commencement of any work installing the tank, the foundation
should be checked for the following.
Foundation
1 Using a transit, check to see the foundation meets the levelness

tolerances noted in “Foundation Tolerances” on page 5-3.
2 The foundation diameter is correct.
3 Center column pad is placed (if required).
4 Adequate slope and compaction of backfill.
5 Confirm the center point and major tank axis are properly identified on
the foundation.
Anchor bolts
1 The correct quantity and starting point of anchors.

2 The correct radius and spacing between anchor bolts.
3 The correct height of anchor projection above top-of-concrete.
If the foundation or anchors bolts are not correct, stop all work and
contact CST for assistance in resolving problems.
7-1
Bottom Construction
1 Lay out plastic and/or fiberboard on foundation as required. It may be
cut roughly to size, but do not cut to actual size of tank bottom until the
tank floor is installed.
2 Identify the zero degree orientation on foundation that matches up
with the corresponding orientation shown on drawings.
3 Locate bottom center plate at the center of the foundation. Put a strip
gasket on top and push bolts up thorough the bottom with bolt retainer
channel (2 or 3 hole).
4 Layout major axis of orientation.
5 If the bottom of the tank has a sump or any penetrations through the
bottom, or buried piping under the bottom, these components must be
located and installed prior to beginning the bottom. Refer to details in
the construction drawing supplied by CST.
6 Lay four bottom segments at major axis with the strip gasket and bolts
on both sides.
7 Prepare and lay the rest of the bottom segments.
For single-piece, pie-shaped bottoms (only one ring of bottom
segments - typically up to and including 32 foot diameter):
a Install all bolts and gasket on top right-hand side of bottom
segments, except the sheets that will mate with the 4 segments
already laid at major axis. Put in all bolts except the inner and outer
circumferential seam bolts.
For two-piece or multiple-piece, pie-shaped bottoms (multiple rings of
bottom segments - typically larger than 32 foot diameter):
a Do not gasket edges or radial seams beforehand. Lay both inner and
outer segments (with circumferential gasket and bolts in between),
then install full length of gasket on both the inner and outer
segments so there is a single length run (no splice). Do the same
with the bolt retainer channel.
For cant bottoms (multi-piece square-shaped floors - typically 55 foot
diameter and larger):
a Start in middle and run the full length row, then work to each side
one row at a time. Install gasket on the leading edge of each row
after it is laid and before laying the next row.

8 Make sure there is no dirt and debris in the strip gasket or on segment.
Wipe off with rag as necessary or blow off debris with compressed air.
9 Lay remaining bottom segments working counter-clockwise (CCW)
(for pie-shaped floors) installing nuts. Bump gaskets should be laid at
center plate and at outer edge with bump down.
10 Once all bottom segments have been laid, then go back and snug with
impact and torque by using torque sticks.
Note: CST recommends the use of torque sticks to get proper torque.
11 Prior to beginning other work, cover bottom with tarp or other

protective material (especially in high traffic areas such as the location
of the manway) to protect it during other work.
12 Once the bottom is complete, recheck the entire assembly.
a Visually inspect all laps to ensure good, consistent, even
compression and that there is no debris and no wrinkles in the
gasket. Make sure all gaskets have adequately filled all voids.
b Retighten 100% of floor with torque wrench set to 55 ft-lbs, except
at laps which are tightened to 65 ft-lbs (2-3 bolts each side of the
actual lap).
c When using encapsulated nuts, check that plastic has not spun on
the steel nut and that the plastic ring is seated against the floor. Use
a 4-point socket to tighten. Tighten last nut at edge before hanging
the staves.
7-3
Single Sheet or Pie Shaped Bottom Typical Joints
C C
Bottom B B
Center Plate Strip Gasket
A A
Chime Lap Gasket

and Caulk
Section B-B
Strip Gasket
(Radial)
Sq. Hd.Bolt and
Bottom Encapsulated Nut
Segment Bottom (Typ.)
Segment Bottom
Strip Segment
Gasket Strip Gasket
Bump
Gasket
Bottom Bolt Channel
Center Plate (Typ.)
Section A-A Section C-C
Figure 7.1

Cant (Multi-piece Square-shaped) Typical Bottom Joints
B
B
A A C
Strip Gasket Strip Gasket
Chime Lap Gasket

and Caulk
Section A-A Section B-B
Sq. Hd.Bolt and
Encapsulated Nut
(Typ.)
Bottom
Segment
Strip Gasket
Bolt Channel (Typ.)

Section C-C
Figure 7.2
7-5
Notes:

C H A P T E R
TANK ASSEMBLY AND INSTALLATION

CHAPTER8
Sidewall Construction
First Ring
1 Begin by preparing the bottom chime. Install all lap bolts in the bottom
chime and insert wooden 2x4 or 4x4 under lap bolts to push them in
and to create a gap between floor and foundation to assist in installing
chime bolts.
Note: Do not use any material that will damage the coating.
2 Install all bump gaskets bump side down. Do not apply caulk yet.
Layout strip gasket and install all regular length chime bolts. If a strip
gasket must be spliced, overlap the strip gasket 3-holes and put a bead
of caulking at the end of each piece. Do not caulk ends of bump gasket.
3 Identify left-most first bolt for the first stave and remove it. Next
remove corresponding chime bolt for every stave - essentially setting
the layout of the first ring. Also remove any other bolts in the chime
that conincide with vertical seam bolts.
FIRST PANEL CHIME

HOLE
Figure 8.3
8-1
4 Mark all nozzle locations for staves with cutouts with a Sharpie or
grease pen. This will indicate where specific nozzles or accessories
should be as you set the staves, essentially transferring the stretch-out
drawing to the tank.
5 Install gasket and bolts on right-hand exterior side (non-offset side) of
the first ring in the rack (top edge of rack). As the bolts are inserted
through the hole from the inside of the panel, the strip gasket should be
used on the alternate side of the panel to hold the bolts in place.
Starting at the bottom of the panel, insert two rows of the appropriate
length ½ inch polycap bolts. Skip one row of bolts, insert six rows of
bolts vertically, skip one row of three bolts. Repeat for height of panel.
SKIP ROW
] 6 ROWS
SKIP ROW
] 2 ROWS
Figure 8.4
6 Disassemble the shipping rack as staves are pulled from the rack. The
rack should be secured and anchored so that it cannot shift or fall
during disassembly. Serious injury can result from a falling or shifting
rack of staves that is partially disassembled if not adequately secured.
WARNING:
The rack must be secured or anchored. Failure to
heed could result in serious personal injury or
death.

7 The top right-hand lap corner of each stave must be slightly opened up
across the full width of the vertical seam so that the offset of the next
stave will easily slip inside it. Lift up the edge of the stave
approximately 3/8 inch to ½ inch using a drift pin for light gauge staves
(less than ¼ inch thick) or a chimebender tool for heavy gauge staves
(¼ inch thick or more).
8 Before hanging the first stave, put caulking on all bump gaskets from
step 1 per detail at the floor stave seam. Install bump gasket at left
hand corner of first stave (bump gasket at left of wedge).
9 Set a wooden or plastic wedge on the floor sheet that will remain
between the floor sheet and left hand side of first stave to facilitate
installation of last stave.
10 Begin hanging the first stave by putting first hole in left hand side on
empty bolt hole (that was removed in step 3) and lining up with the
chime bolts and setting in place.
11 Install all nuts on chime and snug.
12 Install a bump gasket on the right-hand side of bottom of first stave
with the bump down and caulk.
13 Install radius gasket at top and bottom and caulk.
APPLY CAULK BOTH

SIDES RADIUS GASKET
APPLY CAULK TO
STRIP GASKET
Figure 8.5
8-3
14 Push back lower 2-3 rows of bolts flush with the gasket so the next
stave will set easier.
15 Support and secure the first stave so it doesn’t fall over.
16 Hang the second stave by catching it over 3 bolts on the bottom chime:
the bolt on the left hand side, the floor sheet lap bolt (also longer), and
one bolt back from the last hole at the right of the stave. The stave
should be hung with the right side higher than the left side and the left
hand bolt shall be pinned first, then stave rotated over the chime and
the right side lowered down to drop onto the other two bolts, then nut-
up and snug.
17 Finish pushing all other chime bolts up and installing nuts (finger
tight).
18 Usedrift pins to walk vertical seam together (on left hand side of the
second stave), starting at bottom and working up, putting on catch nuts
as bolts come through the holes. Must make sure vertical seam strip
gasket at the top does not get pinched when the top of staves come
together and that radius gasket stays in place.
19 Repeat the last three steps to finish hanging the first ring. As additional
staves are installed, brace or secure the first couple staves until an
adequate number of staves are installed so that the assembly is stable
depending on stave thickness, wind conditions, etc.
Note: Do not tighten any vertical seams until later when noted.
20 Once you get to the last stave, knock all chime bolts down except for
the floor lap bolt. Start placing the stave from the right end (behind and
under the first stave where wedge was placed in step 9) then work
towards the left.
21 Remove wedge and drive up chime bolts, then use drift pins to close
up the last two vertical seams.
22 Tighten 100% of the bottom chime.
23 While tightening the bottom chime, simultaneously tighten up catch
nuts on vertical seams.
24 Once chime and catch nuts are tight, then drive-out and nut-up and
tighten all vertical seam bolts. Observe all gaskets to ensure they stay
in place. Tighten all vertical seam bolts. The top two and bottom two
rows of bolts at each vertical seam may need to impacted longer to get

the same compression of the gasket because of the radius of the two
staves being pulled together.
25 The general method for tightening is to watch the push out of the strip
gasket and listen to the impact gun. A typical range for all vertical
seam bolts varies by the thickness of the steel, ranging from 70 ft-lbs
to 100 ft-lbs. See “Bolt Tightening and Torque Specifications” on
page 6-6 for torque specifications.
26 Once all vertical seam bolts are tight, then ream out holes with a 9/16
inch reamer at lap seams only and install longer lap bolts. Minimal
reaming is required, but it must be done. Do not "wallow out" the hole,
just ream straight through.
27 When installing the longer lap bolts, make sure it does not interfere
with vertical seam bolt. Use a neoprene washer on the top and bottom
of holes that are reamed.
28 Hand tighten all chime lap bolts and the bolt to the right (over the
bump in the offset break) as tight as you can get them.
29 Remove wooden blocks under floor. Make sure no hardware is trapped
under floor. Install remainder of fiberboard as floor is lowered.
Second and Subsequent Rings
1 Stage all of the materials for the second and higher rings inside the
tank on the floor with the concave side up. They can be carried in
before setting the first ring, or before closing up the first ring,
depending upon the diameter of the tank. When racks of steel are
placed on the floor, wooden 2 x 4’s or other protective material should
be placed between the floor and the rack. When staves are spread
around the perimeter, they should also be positioned on top of the
2 x 4’s or other protective material.
2 Install the tank scaffolding per the manufacturer’s instructions and
standard operating procedures. CST recommends the tank scaffolding
and fall protection system that can be purchased from Daystar Safety.
Other tank scaffolding systems are not recommended and the user
assumes all liability. A man lift or stick-built scaffolding system are
viable alternatives but are less efficient and more costly methods of
installation.
3 After the scaffolding system is installed, prepare to hang the next ring.
8-5
4 With a hammer, flatten the laps that were previously opened up in step
7 of the first ring installation. Use caution not to damage the coating.
5 Ream lap holes (minimal reaming is required). When installing bolts,
use neoprene washers on both the top and bottom of all reamed holes.
6 Install lap bolts (with neoprene washer under bolt head) then install the
bump gasket (with caulking if ready to hang ring immediately).
7 Install strip gasket on entire chime with 100% of chime bolts except
the bolts need to be left out for layout. Also leave out the bolt
immediately to the left of each vertical seam to be used as a lineup hole
to insert the drift pin.
APPLY CAULK
STRIP GASKET
CHIME LAP GASKET
Figure 8.6
8 Hang the second ring the same as the first, beginning with step 3 of the
first ring installation.
9 Repeat for each subsequent ring of staves.
10 On the second chime and higher, the lap bolts at the vertical seam for
the ring above can be turned over for ease of tightening, but it is not

necessary. The lap bolts at the vertical seam below are not turned over.
Put neoprene washers on both the top and bottom of all reamed holes.
TOP OF PANEL
BOTTOM OF PANEL
2V PANEL 3V PANEL
Figure 8.7
11 Once the top ring is complete with bolts and gaskets installed, install
the rafter clips. Do not ream the top chime until the deck is laid down.
Move the scaffolding to the middle of the top ring (3 feet to 4 feet
down from the top) for installation of the deck.
8-7
Notes:

C H A P T E R
DECK ASSEMBLY AND INSTALLATION

CHAPTER9
Deck Construction
There are several types of deck installations depending on the design
specifications for the tank. All are generally installed the same with some
variation depending on: the type of deck sheet, the support methodology
at the center of the tank or the perimeter of the tank, and the type of rafter
system. Below is a description of the different components and how they
vary. Review the engineering drawings to determine how the roof system
for your tank is designed.
Deck Components
Support at Sidewall of Tank

1 Chime clip
2 Vertical seam clip
3 Column supported
Support in Center of Tank

1 Center-column supported - with rafters supported on bearing plate at
top of center column.
2 Self-supported - main beams with center collar on riser channel to
support rafters.
9-1
Rafter System
1 Main rafters
a Single piece
b Multi-piece
2 Jack Rafters
3 Externally Supported Roof
Deck Sheets
1 Self-supporting (no rafters) - typically less than 21 foot diameter
2 Pie-Shaped (rafter supported) - typically 21 foot up to 47 foot diameter
3 Cant (rafter supported) - typically greater than 47 foot diameter
General Installation
1 Install the gasket and bolts in the deck sheets on the ground in the
leading edge.
2 Install the rafter clips at the sidewall of the tank, if applicable.
3 Install the main deck structure support columns or clips at the sidewall
of the tank, if applicable.
4 Install the main support beams with center collar if self-supported,
OR, install the center-pole with bearing plate if center-supported, as
applicable.
5 Install the rafters (mains and jacks).
6 Install all internal piping and downcomers prior to installing the deck
sheets.
7 Install deck sheets.
8 Tighten deck.
9 Install roof components and accessories.

Specific Installation Details
Support System Installation
Chime Clip Rafter Support at Sidewall

Rafter chime clips hang over the top chime and support the rafter at the
top of the sidewall. This will require longer bolts in the chime at the
chime clip. Bump gaskets (on top with bump down) are needed on both
sides of the chime clip and typically will cover the top of the chime
hanger. The clip must be temporarily bolted in place prior to setting the
rafter.
Figure 9.1
After installing the rafter, the rafter-to-clip bolts do not need to be over-
tightened. After snugging up the nuts, scar the threads of the bolt so the
nut will not come off and then loosen the nut so that the bolt can slide in
the slot of the rafter clip. Another alternative is to double-nut this
connection. Caution must be exercised when placing the deck sheet over
the top so that the rafter clip does not come loose from the chime.
Vertical Seam Rafter Clip Support at Sidewall

A vertical seam clip bolts to the vertical seam with strip gasket between
the clip and stave and support the rafter at the top of the sidewall. When
9-3
installing these rafter clips, they should hang loose until the rafter is
installed.
Figure 9.2
After installing the rafter, the rafter-to-clip bolts do not need to be over-
tightened. After snugging up the nuts, scar the threads of the bolt so the
nut will not come off and then loosen the nut so that the bolt can slide in
the slot of the rafter clip. Another alternative is to double-nut this
connection. Installation of the deck sheets is much easier if the rafter can
slide in the sidewall clip. After entire deck with sheets is installed, the
vertical seam clip can be tightened from the outside by tightening the
vertical seam bolts.
Column Support at Sidewall

Columns are used to support the main deck structure beams at the
sidewall for self-supporting roofs and typically are located down a few
feet from the top of the sidewall. They can be used in conjunction with
either the chime clips or vertical seam clips for the rafters above them.
The columns are typically installed on the tank interior with separate
holes punched into the sidewall of the tank and gasket placed between the
column and the sidewall. The bolts through the sidewall should be

tightened prior to setting the main beams. The main beams may be either
bolted or welded to the column supports as called out on the drawings.
Figure 9.3
Center-pole Supported Roof

The center-pole roof has a pole to grade to support the rafters in the
center of the tank. The center pole is typically more than one piece and
should be bolted together prior to standing it up. The base sets in the
center of the tank and is generally not fastened to the floor unless
specified in the drawings. There is a rafter bearing plate with a collar that
slips over the top of the center pole and typically is not fastened to the
pole. A row of holes around the outside of the bearing plate is where the
rafters are bolted to the bearing plate. All nuts should be tightened and
the threads scarred. The bolt head should be on top so that it cannot fall
out if the nut comes loose.
Figure 9.4
Prior to standing the center pole in the tank by crane or other safe
methods, build a scaffold tower (or use other approved access
9-5
equipment) in the center of the tank to access the top of the center pole.
The scaffolding may not be used to secure the center pole. Once the
center pole is stood up, immediately install a minimum of 3 equally-
spaced rafters, using a crane or other safe method, to secure it to the tank
sidewall. Once the pole is secure, begin placing the other rafters,
connecting both to the clip at the sidewall and the bearing plate in the
center.
Self-supported Roof
The self-supported roof does not have a center pole, but instead consists
of two large main beams that are supported at the perimeter of the tank
walls by clips or columns and free-span the entire diameter of the tank.
There are typically multiple cross-braces between the two mains that
connect them.
Figure 9.5
In the center, there is typically channel or angle risers which support a
collar or rafter ring to connect the rafters. Depending on the tank size and
design, the size and mass of this support structure (the main beams, the
cross-braces, and the riser channel with the support collar) are typically
pre-assembled on the ground and set in place by crane. Many times the
main beams are too long to be one piece and so multiple pieces must be
assembled to make one main beam. When there are two main beams, the
splices must be offset so one splice is never directly across from the other
splice. No gasket should be used in these connections and when A325
structural hardware is specified, it must be snug-tightened as specified

beginning on page 6-6 in the “Bolt Tightening and Torque
Specifications”section of this manual.
Figure 9.6
Rafter System Installation
Single-piece Main Rafters

The single piece rafters are placed once all sidewall clips and the center
pole with bearing plate or self-supported beams with rafter collar are
installed. Set the four rafters at the major axis of the tank, then begin
installing other rafters to fill in, working counter-clockwise. Leave rafters
loose until all are installed and the top of the tank is rounded out
Multi-piece Main Rafters

Pre-assemble the inner and outer rafters on the ground and use a crane to
place. When A325 structural hardware is specified, it must be snug-
tightened as specified beginning on page 6-6 in the “Bolt Tightening and
Torque Specifications” section of this manual. Install with same method
as the single-piece main rafters.
Jack Rafters
Jack rafters are set between the main rafters when required by design.
They connect to a sidewall clip and a tie-brace that spans between two
main rafters, typically near the mid-point of the length of the main rafter.
It is generally easiest to loosely install the clips on the respective main
rafters with the tie-brace loosely hung on one of the clips. This is done on
the ground and set in place with the main, then once all rafters are
9-7
installed, the tie-brace can be connected to the second clip and tightened,
and then the jack rafter installed.
MAIN RAFTER
JACK RAFTER
Figure 9.7
Externally Supported Roofs

Refer to the ESR Installation Manual from CST for installation
instructions.
Deck Sheet Installation
Self-supporting Deck Sheet

This roof sheet design has no rafters or rafter clips and is only used on a
one-piece roof. There is a bolt-retainer angle that attaches to the vertical
leg of the deck sheet and keeps the bolts in place and should be pre-
assembled on the ground.
½" ROUND HEAD
BOLT & NUT
STRIP GASKET ½" FLAT WASHER
DECK SHEET
BOLT-RETAINER ANGLE
½" SQ.HEAD BOLT &
NUT
½" FLAT WASHER
Figure 9.8

There are one or two main rafter beams that connect to the vertical seam
of the sidewall by a rafter clip. In the center are riser channels (2-beam)
or riser angles (1-beam) to support the manhole collar/dome neck. The
inner side of the deck sheet sets on the manhole collar/dome neck and the
outer side of the deck sheet sets on the top chime of the tank. After
setting the first deck sheet, prepare and install the rest of the deck sheets
in a counter-clockwise manner (similar to floor).
Figure 9.9
Pie-shaped Deck Sheets

The layout of the pie-shaped roof is very similar to that of a pie-shaped
floor. Starting from the outside ring of the deck sheets so that subsequent
inner rings of sheets are on top - creating a shingled effect to shed
rainwater - lay the deck sheets counter-clockwise. If multiple rings exist,
work inward, continuing to lay subsequent rings counter-clockwise. The
deck sheets can also be laid out so that there is a full length strip of gasket
on both the inner and outer sheet radial seams (no splice).
Cant Sheets
On cant roofs, start at one side and work towards the middle and stop at
the last full sheet, then go to the other side (180 degrees from the starting
point) and work towards the middle again) till the last full sheet is
installed. The closing seam will be installation of the two narrow sheets
down the middle. Each long seam should be laid as a continuous piece of
gasket. The sheets should be placed so that each quadrant is shingled and
will shed rainwater. This will require lapping the sheets in each quadrant
appropriately so that the edge of a sheet does not create a dam that blocks
9-9
the runoff of water. All sheets should be loosely hung until complete to
facilitate easy installation.
Completion
1 Once the deck is installed, finish installation of the tank by installing
all accessories.
2 As the scaffolding system is disassembled, clean and wipe the tank of
debris and check the coating for any defects that require touch-up.
3 Broom clean the tank floor to remove all debris.
4 Connect all valves and piping and close all manways to prepare tank to
be filled for hydrostatic testing. See “Hydrostatic Test Procedure” on
page 12-1.

C H A P T E R
MISCELLANEOUS
CHAPTER10
Field Locating Nozzles

1 Identify the tank stave where nozzle will be located.
2 Determine the height and degree of location on exterior of tank stave.
3 Mark centerline horizontally and vertically.
4 Position the nozzle gasket on the centerlines making sure the vertical
centerline is straddling the mounting holes at the top of the nozzle
(2-holed).
C
L
Figure 10.1
10-1
5 Use the nozzle gasket as a template and mark the nozzle inside
diameter and mounting holes onto stave.
6 Use a metal saw to cut out nozzle opening. Do not torch cut.
7 Touch-up edges of stave with touch up paint per touch up instructions.
8 Drill mounting holes using a 9/16 drill bit.
9 Push bolts from inside out into gasket in all mounting holes (gasket
will hold bolts in place until nozzle is positioned onto bolts).
10 Apply neoprene washers to all bolts.
11 Torque all nuts to minimum 50 foot pounds.
Note: Nozzles 8 inches and larger require an interior backing plate. The
procedure is the same as above except all work to be performed from
inside the tank.
Coating Touch-up
All coated tank components are shop-coated at the manufacturing
facility. The factory inspection includes holiday testing and dry-film
thickness measurement as required by CST's Manufacturing Quality
Assurance Manual. To minimize damage, care should be taken when
handling the coated steel during unloading, handling and installation.
This includes making sure tools or falling hardware do not damage the
coating; that the amount of mud, rocks, and sand brought into the tank
during installation is minimized, and that care is taken when using lifts or
mechanical equipment. However, despite the best efforts in the course of
shipping, handling, and installation, there may be some damage to the
coating.
A touch-up coating system is provided by the factory for touch-up in the
field. It is typically applied concurrent with the installation of the tank by
the installer (on the interior) and concurrent with the removal of
scaffolding (on the exterior). Other plans for touch-up are acceptable as
long as a thorough and complete visual inspection is performed. The
coating on the floor should be inspected after all tank installation work is
complete.
The primer coat system is Trico-Bond EP and it shall be applied to all
damage where the existing coating has been damaged to the substrate and
bare metal is visible. The Trico-Bond EP primer shall be applied in
accordance with the procedure in Appendix A.
10-2 HydroTec Tank Construction Manual

The topcoat system is a urethane system and shall be applied to all
exterior surfaces that have an existing Trico-Bond EP primer coat that is
protecting the substrate. The urethane topcoat shall be applied in
accordance with the procedure in Appendix B.
If a field-holiday test is desired, it should be performed by the customer
after the installation of all piping and equipment in the tank.
MSDS information is available from CST upon request.
Welding
All welding performed in the field as required by CST's engineering
drawings shall be performed by welders qualified to applicable American
Welding Society (AWS) and/or ASME Section IX Standards.
Welding to the tank is not recommended except as noted on the CST
engineering drawings. Protective measures, such as fire blankets or equal
steps, should be taken to preserve the coating around the area that is
being welded. All coating shall be touched up after welding is complete.
10-3
Notes:

C H A P T E R
APPURTENANCE INSTALLATION
CHAPTER11
Flush Cleanout Assembly
½" NUT ½" NEOPRENE

BACKED WASHER 1 ROW GASKET
APPLY SEALER WHERE
VERTICAL & HORIZONTAL
BAR PLUG GASKETS OVERLAP
½" HEX
BOLT
½" HEX BOLT
½" NEOPRENE 1 ROW GASKET

BACKED WASHER
½" NUT ½" HEX BOLT
HEAVY STEP GASKET 3 ROW GASKET
Figure 11.1

Shell Manway
MANWAY &
BACKING PLATE
½" HEX BOLT
½" NUT
GASKETS
APPLY SEALER WHERE
VERTICAL & HORIZONTAL
½" NEOPRENE GASKETS OVERLAP
BACKED WASHER
Figure 11.2
11-2
Nozzle with Backing Flange
BACKING FLANGE
(IF REQUIRED)
NOZZLE
½" NUT
GASKET ½" NEOPRENE

BACKED WASHER
½" POLYCAP BOLT
Figure 11.3

Overflow
OVERFLOW
NOZZLE
(OR ELBOW)
½" NUT
½" POLYCAP BOLT ½" NEOPRENE

BACKED WASHER
GASKET
Figure 11.4
11-4
Liquid Level Indicator Assembly
For tank with a deck or dome, determine the location for the gauge board
along the tank perimeter. Mark the center hole on the deck/dome for the
pulley pipe flange. Locate and mark the holes for the two tensioner
flanges on either side of the center hole as indicated.
2" DIA. HOLE WITH (4) 9/16"

HOLES ON A 3 1/2" B.C.
TYPICAL
16"
8.5" 8.5"
Figure 11.5
For open top tanks, install the level indicator top bracket onto the six
holes located in the wind girder. Position the bracket such that the pipe
plug holes are positioned to the interior of the tank.
Figure 11.6

Install the gauge board splice bracket to the underside of the wind girder
using the supplied holes.
Figure 11.7
Attach the two top anchor assemblies to the outermost pipe plugs.
Figure 11.8
11-6
Gauge Board Installation
Starting at the top of the tank, assemble the gauge boards by attaching
one splice bracket to either end using four ¼" truss head screws, inserts,
and lock nuts.
Figure 11.9
Attach one support bracket at the chime using the existing bolts.
Continue installing the gauge boards to the tank at every horizontal seam.
Figure 11.10

Pulley Installation
Assembly the pulley assembly and attach it to the center pipe plug on the
bracket/deck.
Figure 11.11
Attach the pipe section to the gauge board assembly using a U-bolt.
Figure 11.12
11-8
Guide Wire and Float Installation
Drop a plumb line from each tensioner assembly to the floor and position
the bottom anchor angle on the floor such that the guide wires will be
plumb. Attach the bottom anchor to the tank bottom.
Temporarily tie off one end of the guide wire. Thread each of the guide
wires down through the tensioner assemblies to the floor of the tank.
With the float resting on the tank floor, thread the guide wires through
the float guides. Insert the guide wires through the appropriate holes in
the bottom angle. Secure the end of each guide wire to the adjacent hole
using the supplied fasteners.
Figure 11.13
To provide adequate tension on the guide wire, compress the spring 1-½"
to 2" and bend the wire over the rod. Wrap the wire around the rod and
install the keeper sleeve over the wire and tensioner. Repeat for the other
tensioner.

Calibrate the Indicator
Connect the float cable to the float using the cable crimp. Thread the float
cable up through the pulley piping.
Figure 11.14
Install the indicator onto the gauge board assembly.
Calibrate the indicator target to zero and attach the end of the float cable
to the target.
Check that the float and indicator are free to travel up and down the guide
wires without interference.
Figure 11.15
11-10
Completed installation views.
SIDE VIEW FRONT VIEW
Figure 11.16

Notes:
11-12
C H A P T E R
HYDROSTATIC TEST PROCEDURE

CHAPTER12
General
The purpose of the hydrostatic testing of a liquid tank is to ensure that all
of the sidewall and bottom joints are sealed by simulating the head
pressure of a tank in service by filling the tank with water and visually
inspecting the exterior for leaks. Bolted tanks have seams and
connections and it is not uncommon to have a few leaks when the tank is
first filled.
Leaks can be held to a minimum by:
• ensuring that all gaskets are installed correctly (no debris, folds, or
creases),
• all sealant is applied properly at gasket splices, chime laps, and stave
corner radii,
• and all bolts are visually double-checked to see that washers and nuts
have been installed and tightened.
Since a tank must be drained to fix a bottom leak, CST recommends that
all of the bolts in the floor of a liquid tank be double checked prior to
closing up the tank for filling to minimize the potential for a floor leak.
Check the floor fasteners manually with a socket and torque wrench for
proper torque.
If fiberboard is present under the tank and was wetted by rain during
construction, it may take up to a week for the fiberboard to dry out and
stop oozing water.
A vacuum box test is an alternative method of checking the floor, but is
not considered more conclusive.
12-1
Fill Tank and Inspect
After proper tank construction has been completed, the Owner is
responsible to install all manway covers, valves, appurtenances, and
blind flanges to cover all openings on the tank.
Once the tank is sealed and water source connected, proceed with filling
the tank. Due to a wide variance in the available pressure and flow rates
from the supplied water source, the duration required to fill the tank
varies.
During the filling process, the tank should be monitored periodically.
Any leaks can be repaired as they are discovered. The tank may be filled
either to the maximum working level or to the overflow level.
After the tank is full, perform a thorough visual inspection of the shell
and perimeter of the foundation to determine if there are any leaks. CST
does not recommend a minimum hold time, but it may be beneficial to
allow the tank to sit for approximately 24-hours prior to draining or
transferring the water to another tank to allow any slow leaks to develop,
if any.
The customer or a representative should inspect the tank and accept it
prior to draining. The customer or its representative should inspect the
tank and accept it prior to draining.
Repair Procedure
If a leak does occur during filling or inspection, the following steps
should be followed to repair the leak.
1 Check the leaks first which are highest on the tank. What appears to be
a leak near the bottom may be coming from a leak higher up.
2 Look carefully for the source of the leak since it may follow a seam for
some distance before it can be easily seen.
3 Carefully tighten the bolts next to a leak for about one foot in both
directions. Do not over tighten. It is possible to squeeze the gasket out
of a seam, making it necessary to replace the whole strip of gasket.
Stop tightening when gasket begins to compress. To tighten evenly,
work back and forth from one bolt to another.
4 In some cases, leaks are caused by humps in the steel plates halfway
between bolts especially on lighter gauge steel. Often the most

effective way to stop a leak of this type is to tap the steel around the
leak gently with a ball peen hammer.
5 To stop a leak along the thread of a bolt, remove the nut. Replace the
combination washer with a two piece seal washer CST part numbers
795NR4000 (rubber O-ring) and 791MR4000 (special washer). Re-
install the nut.
12-3
C H A P T E R
OPERATION AND MAINTENANCE

CHAPTER13
General
Continuous and satisfactory operation of the tank requires periodic
inspection and maintenance to identify and correct any potential issues as
they arise. Below is a minimum recommended inspection that should be
completed on a regular basis.
Monthly Inspections
A monthly inspection should be completed by owner or operations
personnel. Any discrepancy or sign of damage should be repaired
immediately.
1 Check for and remove any debris that may have accumulated outside
the tank, particularly any debris that is in contact with the tank shell or
appurtenances attached to the tank. Remove any mud, oil, or other
foreign material on the tank shell.
2 Check all seams for any signs of leaks. If a leak is detected, check
tightness and tighten all bolts within one-square foot area of the leak.
Monitor the area until leak is eliminated.
3 Check all seams for any distortion that may have occurred from undue
structural stress.
4 Check to make sure that there is sufficient drainage away from the
tank and no water is standing under or near the foundation.
13-1
Annual Inspections
An annual inspection should be completed by the owner to ascertain the
condition of the tank. The inspection should identify any signs of
corrosion, product leakage, coating damage, equipment malfunction, and
any other item related directly or indirectly with the performance or
safety of the tank. All corrective action should be completed immediately
after a problem is identified. In addition to the monthly inspection, the
following should be examined.
1 Examine the concrete ringwall or slab foundation for fractures that
may have developed. Fractures or other distortion can cause eccentric
loading on the steel tank and may lead to structural damage or failure
2 Check for voids or gaps between the tank bottom and the concrete
ringwall or slab foundation that may be caused by foundation
settlement.
3 Check the anchor bolts and grout (if applicable) to ensure the nuts are
tight and grout is not cracked.
4 For tanks with granular foundations, check for washouts or other signs
of loose or missing backfill.
5 Examine the deck for sagging, water standing on the deck, or other
foreign material on top of the tank.
6 Inspect tank for signs of external corrosion or other coating damage
and repair.
7 Inspect all fittings and appurtenances for signs of leaking or loose
connections.
The appurtenances on the tank should be serviced on a regular basis and
inspected annually or more frequently as required.
1 Thief hatches (pressure/vacuum) should be inspected and have the seat
ring and gasket wiped clean. Check the valve for free movement. In
cold environments, inspect for icing caused by condensation. Clean
screen of all debris that it has collected. Check for screen deterioration
and replace if necessary.
2 Free flowing vents should have the screen cleaned of debris and
checked for deterioration. Replace if necessary. In cold environments,
inspect for icing caused by temperature difference.
3 Nozzles and connecting pipes should be checked for distortion of the
tank wall at the point of connection or stress within the nozzle or

piping caused by settling between the tank and the piping. This
situation must be remedied immediately.
4 Liquid level indicators should be examined for smooth operation,
build-up of foreign material, or signs of float cable wear or damage.
Check that all connections are tight. In cold environments, check for
ice build-up.
5 Visually inspect all valves, sample boxes, sight glass, pressure gauges,
and all other appurtenances located on the tank.
6 Inspect the external ladder, platforms, and handrails for damage or
loose bolts.
7 Inspect all lightning rods, conductors and connections.
Periodic Internal Inspections

The tank should be drained and internally inspected initially within the
warranty period, and then at least every three to five years thereafter, or
more frequently if the owner determines that conditions warrant an
internal inspection or if required by local, state, or national laws and
regulations.
The owner should provide knowledgeable personnel familiar with tank
entry and should follow all safety rules regarding tank entry, including
but not limited to isolation of potential energy sources, identification of
any potential hazards, and confined space entry procedures.
An internal inspection may require removal of any sediment that has
accumulated in the tank and the tank may need to flushed or cleaned out.
Any discrepancy or sign of damage to the tank or coating should be
repaired immediately. An internal inspection should include, but is not
limited to, the following:
1 Check complete interior, including deck structure, underside of deck,
internal ladders, interior nozzles and appurtenances, and other
structure for signs of corrosion or other damage.
2 Check internal coating for signs of wear or corrosion caused by flow
of liquid, mechanical damage, or coating failure, or damage caused by
stored product.
3 Inspect and tighten nuts on the bottom of the tank.
4 Examine the deck and deck structure for any distortion or sign of
structural stress.
13-3
After the inspection and all repairs are complete, remove all materials,
equipment, and tools and clean the tank as required for product quality.
General
Inspections can be made by the owner's personnel or other qualified
personnel. If this is not feasible, or the severity of the problem warrants
the need, an experienced tank technician can be hired through CST's
Field Service Department.
If any touch-up repairs are required to the coating, CST can provide a
standard touch-up procedure based on the existing coating. Contact CST
for touch-up procedures and materials.
It is recommended that spare hardware be kept on hand to cover normal
maintenance or emergency situations. Because of the many types and
sizes of tanks and hardware available, contact CST for your particular
application. Generally, parts on hand should include gasket material,
caulking, bolts, nuts, and washers. Gaskets and hardware should not be
re-used once they have been removed.
Installation of new nozzles or appurtenances or a change of service may
void the warranty of the tank. If the tank is being considered for a change
of service, the specific gravity of the new liquid must be less than or
equal to the liquid previously stored in the tank. It is recommended that
any such service or physical changes should be brought to the attention of
CST PRIOR to the change.

Notes:
13-5
C H A P T E R
APPENDIX
CHAPTER14
14-1
Appendix A - Trico-bond EP Touch-up Procedure

14-3
Appendix B - HP Urethane Topcoat Touch-up Procedure

14-5
282245-000
ECN 14250 R. 2

Tank Construction: Hydrotec Cs Guide

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Tank Construction: Hydrotec Cs Guide

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HydroTec CS TM

Trico Bond EP®

Introduction 1-1 Fall Protection - Standard Operating

Drawings . . . . . . . . . . . . . . . 1-1 Fall Protection System . . . . . . . . 4-1

Unloading Materials . . . . . . . . . 1-2 Fall Protection Components . . . . . 4-3

Wind Speed Awareness During Foundation Types . . . . . . . . . . . 5-1

Tools and Equipment 3-1 Tank Components and

Tank Assembly and Installation 8-1 Repair Procedure . . . . . . . . . . 12-2

Sidewall Construction . . . . . . . . . 8-1 Operation and Maintenance 13-1

Deck Construction . . . . . . . . . . 9-1 Monthly Inspections . . . . . . . . . 13-1

General Installation . . . . . . . . . . 9-2 Annual Inspections . . . . . . . . . 13-2

Specific Installation Details . . . . . . 9-3 Periodic Internal Inspections . . . . 13-3

Completion . . . . . . . . . . . . . 9-10 General . . . . . . . . . . . . . . . 13-4

Miscellaneous 10-1 Appendix 14-1

Appurtenance Installation 11-1

Tank Detail Print

Tank Stretch-out Print

Various Miscellaneous Drawings

CST Preferred Unloading Method

1-2 HydroTec CS Tank Construction Manual

Carefully plan ahead for storage of materials. If possible, all materials

Inventories and Inspection

Any discrepancies not reported to CST Project Management within seven

1-4 HydroTec CS Tank Construction Manual

SAFETY AND ACCIDENT PREVENTION

Builder Safety Guidelines

Personal Protective Equipment (PPE)

1 Ear Plugs 4 Hard Hat

2-2 HydroTec CS Tank Construction Manual

Securing the tank

CST Storage tank hardware is specifically designed to handle the

2-4 HydroTec CS Tank Construction Manual

TOOLS AND EQUIPMENT

Suggested Tools and Equipment

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3-4 HydroTec CS Tank Construction Manual

3-6 HydroTec CS Tank Construction Manual

FALL PROTECTION - STANDARD

Fall Protection System

2 ft Safety Factor (C)

LL= Lanyard Length

4-2 HydroTec CS Tank Construction Manual

Shock Absorbing Lanyard Fall Clearance Calculation With

When connecting the shock absorbing lanyard to a fixed anchorage or

Self Retracting Lifeline Fall Clearance Calculation

Fall Protection Components

28 15/16" (Heavy Bracket)

The guardrail system consists of the following:

4-4 HydroTec CS Tank Construction Manual

Horizontal Lifeline System

Harness and Lanyards

Only harnesses and Force 2 shock-absorbing lanyards by DBI-Sala are

4-6 HydroTec CS Tank Construction Manual

Fall Protection Rescue

Installation and Use of Fall Protection System

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4-10 HydroTec CS Tank Construction Manual

FOUNDATIONS AND SITE PREPARATION

A ringwall is a concrete ring that is partially buried in the soil. The

5-2 HydroTec CS Tank Construction Manual

Grade Bands for Liquid Tanks

Grade bands and the backfill shall be level within ±¼ inch.

Slabs and Ringwalls