CM07 Sphere Construction

Construction Manual No.
HORTONSPHERES
Rewritten August 1999

By: Charles L. Buchanan
Revised September 2003

By Carl Dube
COPYRIGHT  2003
BY
CHICAGO BRIDGE AND IRON CO.
All rights reserved
The information contained herein is proprietary and confidential. All documents remain
the property of Chicago Bridge and Iron Company and are to be used only in connection
with the performance of work by Chicago Bridge and Iron Company. This manual, and
any information contained herein, shall not be disclosed to any person other than
employees of Chicago Bridge and Iron Company or one of its affiliated companies.
Reproduction in whole or part is expressly forbidden.
CB&I CONSTRUCTION MANUAL 7 REVISION LIST PAGE # 1
September 2003
Para. 1.5. Section I: Revised wording regarding location of column scaffold bracket
straps when shop installed.
Para. 2.6 Section C: Revised to require use of a torque wrench when tightening guyline
wire rope clips.
Para. 3.0: Revised to show that Tank Builder Scaffold rules are now in RBS 155-6-9-2
Part 4 – Minor editorial changes
August 1999
This is a complete rewrite of old Manual 7. The major differences are:
1. Part 1 is devoted to the planning required of the Construction Supervisor. Eighteen

different topics are discussed; from sizing the crane, to how long it will take to pump up
the sphere for testing. See the index for a list of the topics.
2. Flat plate bracing has replaced the rods and turnbuckles used in previous issues.
The bracing is not required on the sphere until test. Paragraph 2.10 recommends that
the bracing not be installed until the scaffolding between columns can be removed.
3. Paragraph 1.4 explains the standard bevel system that defines which side welds
first. In most cases the fitting is done on the side to be welded first.
4. Compression frames are included as an alternate to outside guys when site

conditions make guys difficult or impossible. See Part 2 paragraph 2.6 & Fig. 2-7.
5. Several alternative support systems for lower hip sheets (guys, timber, or pipe) are
presented in Part 2 paragraph 2.7 and Fig. 2-9
6. Pipe support systems for upper hip courses are presented in Part 2 paragraph 2.9
and Fig. 2-13 and 2-14.
7. The proper procedure for fitting dished plate verts by flushing both ends first is stated
in Part 2 paragraph 2.13 B.
8. The scaffold section, Part 3, specifically requires overhead protection at entry points
and barricade tape on the perimeter. Toe boards or equivalent are required around the
opening in the bottom to deflect any dropped objects.
9. Flexible steel ladders, 2L1-20-A, are recommended for permanent access ways
during construction (below equator inside and above outside).
10. Scaffold layouts are included for 20 standard diameters (22’-3 to 91’-6). Sixteen of
the diameters are presented as both standard and wide plate layouts, as explained in
Part 3 paragraph 3.11.A.
11. Trap doors are recommended for all scaffolds in paragraph 3.11.D.
Revised Sept 2003 /CD REV 1

CB&I CONSTRUCTION MANUAL 7 REVISION LIST PAGE # 2
12. Scaffold layouts include the laps of boards onto brackets for all rings of scaffold (to
provide some basis for deciding if the scaffold can be moved up or down). The laps also
enable the CS to determine if the layout can be used on a non-standard size with the
same plate layout. See paragraph 3.11.G
13. The quantities of boards and brackets on the scaffold layouts are exact count. The
CS should add for breakage, inspection scaffold, overhead protection, and the tube and
clamp or other manufactured scaffold under the sphere.
14. Column scaffolds are now located with dimensions given from the equator because
column splice elevations are not fixed by engineering.
15. Dimensions from the inspection scaffold frame to the top peak of each overhead
seam are provided for each sphere based on the hanger lengths shown in the manual.
Engineering is to provide board type superstructure 6’-8” below the peak of each seam
with an extra foot of angle for adjustment. The superstructure will be billed unless the
CS cancels the superstructure, changes to a staging type superstructure or cancels the
entire inspection scaffold.
16. The outside hangers (on the perimeter) for all inspection scaffolds are dimensioned
in the manual. Engineering will provide the angles 4’ in length as they have in the past.
Field adjust to dimension in manual or to suit.
17. Several of the smaller spheres now use painters’ picks (scaffold stage) in lieu of an
inspection scaffold. The pick is suspended above the top scaffold with a “canary swing”
(bolted angle U frame) which must be field fabricated with material ordered by the CS.
18. The inspection scaffolds for 81’-10, 87’-0 & 91’-6 standard diameters require a
batter on the support angles on the outer circumference, because the head opening is
larger than the 46’ diameter scaffold. See paragraph 3.12.F and Fig. 3-13.
19. A section on spiral stairway erection is included in Part 4 paragraph 4.4.
20. A section on layout using spherical geometry (great circle and small circle arcs) has
been added in Part 4 paragraph 4.8.
Revised Sept 2003 /CD REV 1

CB&I CONSTRUCTION MANUAL 7 INDEX PAGE # 1
PART 1 PLANNING BY CONSTRUCTION SUPERVISOR
1.0 PLANNING REQUIREMENTS
1.1 SITE SETUP
1.2 CRANE SIZE
1.3 GROUND ASSEMBLIES
1.4 BEVELS – DOWN VS. OVERHEAD
1.5 SCAFFOLDING AND ACCESS
A. SCAFFOLD THE BOTTOM HEAD OVERHEAD
B. ENTRYWAY WITH OVERHEAD PROTECTION
C. TOE BOARDS AROUND BOTTOM OPENING
D. WITH GROUND ASSEMBLIES
E. INSPECTION SCAFFOLDS
F. WITH PWHT
G. LADDERS
H. TRAP DOORS
I. SHOP INSTALLED COLUMN STRAPS
J. BRACKET STRAPS FOR SPHERES < 60’ DIAMETER
1.6 HITCH LUGS & LANDING ANGLES – CS MUST ORDER
1.7 VENTILATION
1.8 WELDING PROCESS OPTIONS
1.9 PRODUCTION TEST PLATES
1.10 FIELD INSTALLED NOZZLES AND MANHOLES
1.11 PREHEAT
1.12 NDE
1.13 GUYLINES AND COMPRESSION FRAMES
Revised September 2003 / CD REV 1

1.14 PIPE SUPPORTS FOR UPPER AND LOWER COURSES
1.15 POST WELD HEAT TREATMENT
1.16 AUTHORIZED INSPECTION REQUIREMENT
1.17 PRESSURE TESTING
A. PRESSURE & VACUUM RELIEF VENTS
B. TEST WATER (FILL RATES)
C. PUMPING UP TO TEST PRESSURE
D. TEST PUMPS
E. PNEUMATIC TESTING
1.18 COLUMN FIRE PROOFING
PART 2 SPHERE CONSTRUCTION
2.1 CHECK THE FOUNDATION
2.2 SHIM THE PIERS
2.3 CHECK POST PLATES AND COLUMNS FOR LENGTH
2.4 FIELD FABRICATION OF POST PLATES
2.5 ERECT AND WELD COLUMNS
2.6 ERECT EQUATOR COURSE
2.7 ERECT LOWER HIP COURSE
2.8 ERECT BOTTOM HEAD PLATES (7 PC. HEAD)
2.9 ERECT UPPER HIP COURSE
2.10 ERECTION & WELDING OF COLUMN BRACING
2.11 ERECT TOP HEAD PLATES (7 PC. HEAD)
2.12 GROUND ASSEMBLIES - METHODS, TURNING, & RIGGING

2.13 FITTING METHODS AND EQUIPMENT
2.14 WELDING PROCEDURES AND SEQUENCE
2.15 CLEAN UP REQUIREMENTS – CARBON STEEL SPHERE – INSIDE AND OUT
PART 3 SCAFFOLDING AND ACCESS
3.0 STANDARD SCAFFOLDING RULES
3.1 BRACKETS AND HANDRAIL POST USED ON SPHERES
3.2 COLUMN BRACKET STRAPS ON COLUMNS 26” ID AND LESS
3.3 BRACKET STRAPS FOR THE INSIDE OF SPHERES < 60 FEET Ø
3.4 THIRD HANDLINES ON COLUMN SCAFFOLDS
3.5 ARRANGING SCAFFOLD FOR WELDER COMFORT
3.6 OVERHEAD PROTECTION AND TOE BOARDS
3.7 ACCESS PATH TO TOP OF SPHERE
3.8 RIGID LADDERS
3.9 FLEXIBLE LADDERS
3.10 SCAFFOLD UNDER THE BOTTOM HEAD
3.11 STANDARD DIAMETER SPHERE SCAFFOLD LAYOUTS (36 LAYOUTS)
A. LIST 20 STANDARD DIAMETERS & 16 WIDE PLATE DESIGNS
B&C. DEFINES WIDE PLATE DESIGNS AND EFFECTS ON SCAFFOLD
D. TRAP DOORS RECOMMENDED
E. BOARD AND BRACKETS COUNTS ARE EXACT COUNT
F. VERT BOARDS NOT USED INSIDE BELOW TOP HIP COURSE
G. NON-STANDARD DIAMETERS AND PLATE LAYOUTS
72 PAGES OF SCAFFOLD LAYOUTS – 20 DIAMETERS

(20 STANDARD AND 16 WIDE PLATE DESIGNS)

3.12 INSPECTION SCAFFOLDS
A. WHEN REQUIRED & RANGE OF SIX STD SIZE SCAFFOLDS
B. SUPERSTRUCTURE METHODS & BILLING BY ENGINEERING
C. HANDLINE METHODS
D. INTERIOR SUPPORT ANGLES WITH SUPERSTRUCTURE
WARNING REF. PLACING BOARDS INSIDE THE SUPPORTS BEFORE

ATTACHING SUPPORTS TO HEAD PLATES
E. STANDARD LOCATION OF SCAFFOLD & HEIGHT OF

SUPERSTRUCTURE (EXTRA FOOT BILLED BY ENGR’G)
F. INSPECTION SCAFFOLDS FOR SPHERES 81’-10 & LARGER
G. SCAFFOLDS DECKED SOLID WITH BOARDS

(21’-6, 30’, 34’, 42’, 45’, & 46’ DIAMETER SCAFFOLDS)
H. SCAFFOLDS WITH SUPERSTRUCTURE FOR BOARDS

(30’, 34’, 42’, 45’, & 46’ DIAMETER SCAFFOLDS)
I. SCAFFOLDS WITH SUPERSTRUCTURE FOR STAGES

(34’, 42’, 45’, & 46’ DIAMETER SCAFFOLDS)
PART 4 MISCELLANEOUS ITEMS
4.1 PREHEAT – BASIC INFORMATION
4.2 PWHT
4.3 INTERNAL AND EXTERNAL PIPING
4.4 SPIRAL STAIRWAY ERECTION
4.5 SKIRT SUPPORTED SPHERES
4.6 GROUT OF COLUMNS OR SKIRT
4.7 HYDROSTATIC, HYDROPNEUMATIC, AND FULL PNEUMATIC TESTING
4.8 LAYOUT AND SPHERICAL GEOMETRY

CB&I CONSTRUCTION MANUAL 7 PART 1 PAGE # 1
PLANNING BY CONSTUCTION SUPERVISOR
1.0 Planning requirements
The Construction Supervisor should be involved in the precontract effort for the job. In
order to properly estimate the work many major decisions must be made. For example:
1) what size crane will be used, 2) how many and what size ground assemblies will be
made, 3) what welding processes will be used, and 4) what preheat and PWHT
methods will be used, when required. These are just the minimum for estimating
purposes. Other planning must follow when the job becomes a contract. Part 1 will
cover the major planning required both precontract and early in the actual contract
execution.
1.1 Site setup
The amount of area available around the sphere is critical to the execution of the work.
When there is access all the way around the sphere and plenty of laydown and ground
assembly area, the site layout planning can be handled by the Superintendent. But, the
Construction Supervisor must have a plan for tighter sites. Laydown and ground
assembly plans must account for total area available and access will effect crane size
requirements. In extreme cases, a lack of ground assembly area will likely impact the
schedule and the total man-hours required. When a site plan is required, it needs to be
precontract to the extent that the methods to be used are defined.
For contract execution on limited area sites, the Construction Supervisor should make a
sketch of the site showing where; 1) the equipment will be placed, 2) the ground
assemblies will be made, 3) the material will be unloaded, 4) the crane access will be
routed, 5) the site office and storage shacks will be located, and 6) steel delivery trucks
will enter and exit. Sites with fewer restrictions should be reviewed for these 6 items.
1.2 Crane size
The ideal crane for use on a sphere is one that will set the center top head plate directly
in position. If it will do this, it can usually handle the flipping and setting of any ground
assemblies, which might be considered for the size sphere involved. If access is not all
the way around the sphere, check the capacity when erecting the equator and upper hip
course assemblies at the maximum reach required.
A 2 or 3 piece assembly for the top head will save some time in the air and possibly
eliminate the inspection scaffold, but the crane required may not be cost effective
(unless there is not 360 degree access and a large crane is required to set other parts
of the sphere).
If the crane can not set the center top head plate --- the plate may be slid into final
position from a reachable position on an adjacent plate. See Part 2 paragraph 2.11.
The Construction Supervisor must make layouts, to verify capacity, for the maximum
weights and maximum reach lifts on the project, using the crane charts for the rig to be
used.

1.3 Ground assemblies
Ground assembly saves about 1/3 on the welding incentives (down vs. vertical). There
are similar savings in the X-ray crew and there is a smaller saving on the erection and
clean up hours. A major factor in justifying ground assembly (increased crane cost) is
the reduction in schedule due to an increase in number of welders. Contrary to the
opinion of some people, weld quality, as defined by RT percentage, does not tend to
improve unless wind is a problem on the in-position seams.
There will be times when conditions (crane availability and rental) indicate one plate at a
time erection. There is absolutely nothing wrong with that procedure, but recognize the
limits on crew size and schedule.
At CB&I we use three types of layouts for the plates on spheres. They are; 1) orange
peel with horizontal course seams, 2) true expanded cube, and 3) modified expanded
cube with horizontal seams in between. We commonly refer to them as orange peel,
expanded cube, and modified expanded cube.
Expanded cube (type 2)

Orange peel (type 1) Standard sizes
Standard sizes 22'-4, 25'-6 two plates per side Modified expanded cube (type 3) .
28' & 30'-4 diam. 32', 35'-4, & 38' as shown Standard sizes to 91'-6
Wide plate designs Wide plate designs Number of intermediate courses
32' & 35'-3 28', 40'-6, & 43'-6 may vary from 1 to 5.
Fig. 1-1 Standard plate layouts for spheres
In all cases the equator course has a column stub on every other plate. The orange peel
design spheres all require 10 plates around the equator. This eliminates the expanded
cube layout, which requires either 8 or 12 plates around.
The conventional procedure is to ground assemble one post plate and one intermediate
plate in the equator course. Two post plates and one intermediate may be ground
assembled, but extra care is needed to assure the column stubs are parallel and the
chord between stubs is held exactly per the drawings. Both stubs must also be at the
same elevation. These 3 plate assemblies are sometimes erected with only one side
welded to avoid turning the large section.
Modified expanded cube layouts will have an upper hip course on spheres 60’-6
diameter and larger. At 76’ standard diameter a lower hip course is added. Hip courses
can be conveniently ground assembled in 3 plate assembles if a large enough crane is
available and cost effective.
It is important that ground assemblies be welded with the plates cribbed and blocked to
near their final shape. Engineering will supply chord dimensions for shaping the ground
assemblies at the request of the Construction Supervisor. They will need to know the
number of plates to be assembled for each course.
Bottom head plates are usually set as individual plates. The bottom center plate is left
out (or erected and removed) until the scaffolding and inspection scaffold have been
removed from inside the sphere (for ventilation and easy removal of scaffold, as well as
for confined space reasons). Schedule the plates to the site early enough to set them
under the sphere before the top head cuts off access.
Top head plates are commonly set as individual plates due to the reach and capacity
required. If 2 or 3 plates can be lifted as a ground assembly, it will save schedule time
and man-hours – especially if platform and piping can be ground assembled.
The top "side" plates (4 around course of seven piece heads), should not be ground
assembled, except in cases where a very large crane can pick the entire seven-piece
head. The advantage of the 7-piece lift is reduced bullgang and NDE man-hours,
schedule, and the elimination of the inspection scaffold in the top of the sphere (the
short verts and the square will still be position welds on the ground). The upper part of
the shell, which is normally accessed by a ladder leaning on the inspection scaffold, will
have to be completely scaffolded to allow you to plug down. Care must be taken to
assure the fit of the 4 plates to the course below which may have as many as 28 plates.
Also, expect some extra fit up time due to alignment problems with the round seam.
1.4 Bevels – down vs. overhead
The company standard is to weld the more down hand side of all sphere joints first. This
means all joints below the equator will weld on the inside first and those above the
equator outside first. This convention applies to girths as well as verts. The equator
course verts for most spheres are detailed to weld outside first. The exception occurs on
spheres in the 60’ range on which 90% of each equator vert is below the equator. These
weld inside first. The standard bevel convention offers the following advantages,
especially on the head plates:
• More electrode is deposited downhand resulting in larger electrodes and

lower piecework rates. (This could be somewhat countered by unbalancing
the bevels)
• The downhand first pass penetrates more resulting in less backgouge depth
on the second side and substantially less overhead welding.
• Overhead backgouging is cleaner and not at all difficult. (but, there will be
very little work in the lower sphere while the arc gouging is going on.)
The primary disadvantages of welding the downhand side first are said to be the
welding through key plates and the rat holing of finger bars. Removal of finger bars and
key plates just ahead of the first fill pass will overcome most of this. On thin material
(1/2” or less) it may be necessary to replace the key plates or weld through them.

If the Construction Supervisor and Weld Manager want something other than standard
bevels on a sphere, Engineering Assigned must be advised upon award, but preferably
during the precontract stage.
1.5 Scaffolding and access
The Construction Supervisor must plan the scaffolding on a sphere in order to make his
tool list. In Part 3 of this manual scaffolding arrangements (including inspection
scaffolds) are given for all standard sizes of spheres.
The CS must analyze the job and decide what equipment will be sent. The bracket and
board quantities given in Part 3 assume each level to be a closed circle of scaffold both
inside and out. Quantities given are exact count. The CS must add for breakage and
any extras including the inspection scaffold, the bottom head overhead scaffolds, and at
least one entryway with overhead protection. Also add for trap doors if used.
A. Scaffold the overhead on the bottom head seams using tube and clamp or
other manufactured type scaffold. This will vary with the diameter and height above
grade of the sphere. Provide at least two scaffolds the length of the head plate seams (3
piece square head).
B. Provide a minimum of one entryway with overhead protection from six feet
outside the outermost scaffold to six feet inside the column scaffold. Tube and clamp or
other manufactured scaffold covered with scaffold boards is the typical method used.
The remaining perimeter should be marked with barricade tape as on a FBT.
C. Provide toe boards or equivalent around the opening in the bottom head to
prevent a dropped object from sliding down the sphere as a projectile into the open
area. If the bottom center plate is left out the toe boards should surround the entire
opening.
D. When ground assemblies are used, the CS should consider using 8-foot vert
boards on the outside for the position-welded verts. This option is especially beneficial
when 3 or 4 plate assemblies are erected on the hip courses. When using vert boards, a
full circle of scaffold is still required below each girth seam outside and a suspended
work platform will be needed for some of the plugging down. If temporary welds require
MT, the full scaffold may be more efficient due to the 4 nuts required for handline on
each vert board scaffold. See paragraph F if the sphere will PWHT.
Vert boards are not used inside because the inside must be manually plugged down.
Exceptions occur on all spheres 60’-6 and larger. On these sizes the ladder up to the
inspection scaffold is used only for the air-welded verts, so the scaffolding above the
equator to hip course girth seam can be vert boards only. Reduce the number of
brackets and boards for the actual scaffold plan.
E. The inspection scaffold and super-structure, if required, will be drawn and

billed by Engineering Assigned (super-structure for boards). If the CS wants to eliminate
the scaffold or the super-structure (or use staging in place of boards) on one or more

spheres, he must advise Engineering early in the contract. Tube and clamp scaffolding
may be used in place of the super-structure. See Part 3 paragraph 3.12. Note the
super-structure height is adjustable with an extra foot provided for short welders.
On some of the smaller spheres, painters picks suspended from canary swings are
used for overhead access. The CS must order the picks and the swing material.
F. If the sphere is to PWHT, all the outside scaffolding levels must be full circles
(no vert boards). This is to provide access for installation and removal of the PWHT
insulation. Also, the tube and clamp or patent scaffold under the sphere must enable the
crew to install insulation on the full exterior surface. Portable patent or tube and clamp
scaffolds of varying height may be moved from spot to spot for this purpose. See the
individual sphere diameter layouts in Part 3.
G. Ladders must be provided in large quantities.
1) Shell erection ladders are suggested on at least one column.
2) On the lower half inside and the upper half outside, the best option for general
access is the flexible steel ladder 2L1-20. These come in 10’ lengths that splice together
at two blank nuts and bullpens on each end. Wood or fiberglass ladders leaning on the
upper scaffold (between the handlines) may also be used.
3) When the shell is overhead (as on the upper half of the inside), use 8 to 14-foot wood
or fiberglass ladders between scaffold levels for the primary access route up and down
the sphere. The ladders need to extend 3 feet above the scaffold or hand grabs (2L37
or equal) need to be provided 3 feet above the boards.
4) When vert boards are used in lieu of full circle scaffolds, provide wood or fiberglass
ladders for each in position vert (one ladder for every scaffold level on every vert).
Provide enough so ladders may remain in place until the vert is x-rayed and accepted.
Provide hand grabs (2L37 or =) if ladders do not extend 3’ above the boards.
5) Provide about 2 additional 6-foot wood or fiberglass ladders for each welder for use
inside and out as vert ladders and for miscellaneous use.
6) Many spheres require longer ladders (12’ to 20’) for the verts below the inspection
scaffold on the inside. Provide one per position welded vert.
H. Trap doors, as used on flat bottom tank scaffolds, should be used on sphere column
scaffolds where access is by tank erection ladders. It will be necessary to drill holes in
the door (floor) to lag screw the door to the boards or J bolt to the brackets. Trap doors
may also be used as passage ways between scaffolds as used on vertical shells.
I. Significant savings can be achieved by having the shop install the column
bracket straps 2A23 for the scaffold that goes below the column splice. This detail
enables the field to set the columns with virtually no delay, if the crew gets the
foundations shot and shimmed ahead of the delivery.

This is not standard and the CS must request this through Engineering Assigned. The
straps should be put on in accordance with the layouts in Part 3. The bracket strap
elevation depends primarily on the elevation of the equator and NOT the column splice.
Engineering Assigned shall confirm the strap elevation per RBS 4301-3-1, to make sure
that scaffolding will work as planned.
J. Bracket straps for the inside of spheres < 60' diameter can be a problem.
Standard bracket straps 2A22 are designed for flat surfaces. For spheres under 60' in
diameter the versine in the bracket upright length causes the strap to fit tight on the
bracket. The usual cure is to beat the prongs on the bracket down so they will go in the
strap then beat the bracket into the strap (in some cases), then beat the bracket out of
the strap when plugging down. Knocking the bracket prongs down works OK down to
about 50' in diameter. At that point a better solution is to use pole straps 2A24. The only
difference is the depth of the loops. Standard straps are 1½" deep, while the pole strap
depth is 1 15/16". The CS will need to advise Engineering Assigned to bill pole straps
for the inside scaffold.
1.6 Hitch lugs and landing angles
Engineering does not bill hitch lugs or landing angles as part of the expendable erection
material. The CS must determine hitch lug requirements based on ground assembly
plans and requisition them and the landing lugs (1 per equator assembly) with the tools.
See Manual 62 for the hitch lugs and Part 2 paragraph 2.6 for the angles.
1.7 Ventilation
When the overhead work on the top head is being done, forced air ventilation will be
required to clear the weld fumes and for cooling. There are several ways to provide this.
• Use a large fan on the bottom manhole (blowing in). Connection with a large
diameter collapsible duct works very well and greatly reduces the noise if using an
air raise fan.
• Use a large fan on the top manhole (blowing out) with a hinged connection so it can
be swung open for entry and egress.
• Install the fan on top of a site built structure (called a phone booth by the Thailand
crews that invented it) with a flap entry so entry and egress can be accomplished
without turning the fan off. Envision a 4 legged (2 x 2 angle) box, with a bolting
flange on top, welded to the sphere and covered with a flame retardant tarp or light
plywood so it does not leak much.

1.8 Welding process options
Carbon steel (P1 materials) may be welded SMAW (typically E7018), FCAW (Flux core
with Dual Shield wire), or SAW (submerged arc). SAW may be used either with a tilt
table for ground assemblies (standard construction drawing 2B110-1-1) or a mini-girth
welder for in position seams from 5 degrees above horizontal (on the inside) to down
flat. The choice should be made by the Project Manager / CS and the local Welding
Manager based on many factors including: 1) thickness of the material and the impact
requirements, 2) equipment cost and availability, 3) labor cost and availability, 4)
contract requirements, 5) weather conditions to be encountered, and 6) degree of
ground assembly anticipated. Decisions as to welding processes must be made in the
estimating stage --- but they may be changed if conditions warrant after award. If
changed after engineering is started there may be a schedule and cost impact.
1.9 Production test plates
Production test plates are required any time impact testing is done. The CS should see
that the material is billed and goes on the first load of material to the site, and that the
field welds the production test as an extension of the first available joint.
1.10 Field installed nozzles and manholes
The nozzles and manholes are typically located in the head plates and are shop
installed and stress relieved. Occasionally the economics of the freight or the shop cost
will indicate field-installed fittings. If the fittings are to be field installed, both Corporate
Welding and Corporate Construction Technology must be involved in the writing of
specific instructions to the field for maintaining the weld quality and shape of the plate
assemblies. Field PWHT of the assemblies may be required.
1.11 Preheat
Continuous, 200° F, preheat is typically required when P-1 carbon steels are over 1¼
inches thick. This is to avoid PWHT required by Code when the deposited weld
thickness exceeds 1¼ inches. By preheating to 200°, PWHT can be eliminated until the
deposited thickness exceeds 1½ inches at which point PWHT becomes mandatory.
High strength carbon steels (70 ksi tensile and above) require 200° F continuous
preheat above 1 1/8 inches when the ambient temperature drops below 50° F while
welding is in progress. The ambient temperature may be a judgement call and needs to
be established in the estimating stage of the contract. Insert plate assemblies ¾ inch or
greater in thickness also require 200° F continuous preheat when welded into high
strength shell plate.

Temporary welds, tacks and pick-ups on high strength materials over 1 1/8 inch thick
require local 200° F preheat when the ambient is below 50° F, and 100° F local preheat
if the material is 1 1/8 or less thick. If the ambient is over 50° F, 100° F local preheat is
required if the high strength material is over 1 ¼ thick.
Low strength steels require 100° F local preheat, when temperatures are under 32° F
for all thicknesses and when over 32° F for material over 2” thick.
The CS should see CB&I Standard 895-1-1 & 895-1-2 for details needed before the
WPS is written for the contract. The requirement for preheat of both permanent and
temporary welds must be established early and estimated, then the CS must get the
necessary equipment on the tool list. The number of inside and outside preheaters
required is related to the number of welders to be used on the job and the length of the
individual weld joints.
See Construction Manual 64-Preheat, for methods and equipment for the continuous
preheat and Construction Manual 39-Propane Gas Use for propane safety and
formulas for calculating flow and usage rates. The CS needs to make sure the
Superintendent has copies of both these manuals on the job and that an explosion and
oxygen meter is available.
Propane with the flexible, lightweight, Conley Preheaters (standard drawing 2C9-3) is
often used due to the low initial cost of the equipment and the ease of forming the
heaters to the sphere radius. The disadvantage of the Conley heaters is the “lazy flame”
which makes them very inefficient as compared to heaters with blast tips (standard
drawing 2C9-5). Blast tip heaters may use inspirated or compressed air. Compressed
air makes the blast tips even more efficient. Due to the time required to bring the metal
to temperature, Conley Preheaters should not be used in windy or very cold conditions
or with very thick material (say 1.75” and up).
In cold weather, propane vaporization rates slow to the point that a vaporizer may be
required. See Manual 39. The vaporization rate is reduced by about half from 70 ° to
20° F. At 0° F the rate is about 1/3 of the 70° F rate.
Electric preheat becomes a serious consideration when there is free power in adequate
quantities to run the heaters, there is a policy prohibiting open flames on the site, or the
site is extremely cold and a propane vaporization system is not available. See Manual
64.
Use of insulation blankets along side the seam on both the heater and welding side
should be considered to cut down on heat loss, make the welders more comfortable,
and make the joint warm up faster and cool down slower.

1.12 NDE requirements
Spheres typically require RT, MT, SFT, Visual, and occasionally UT to varying degrees
dependent on code, customer, and CB&I requirements. All NDE equipment, material,
and personnel must be planned and their interface with the welding and fitting
accounted for. The CS should work closely with the local Welding / NDE people in
planning this phase of the job.
Customers sometimes require 100% RT or MT after PWHT or after test. Either is

obviously very expensive due to access requirements and risky (if defects are found). A
very precise plan is required in the estimating phase of the job. Corporate Welding
Technology should be involved precontract. Typically, we will perform the NDE both
before and after to minimize the risk of finding rejectable defects after the PWHT or test.
1.13 Guylines and Compression Frames
When the equator course is erected on the columns, each post plate or assembly
should be guyed to the inside and outside as it is erected. The open-end post plates
must remain guyed, so a minimum of 3 sets of three guys are required for the equator
course. The guys should be designed for the conditions expected. Corporate
Construction Technology can help with this if requested. The Construction Supervisor
should provide equipment for guys and a plan or equipment for the deadmen. Existing
foundations, heavy equipment, and sphere plates in the shed water position may make
adequate deadmen. Other times two-pipe deadmen (manual 13) or screw anchors may
be needed. The inside guys attach to the opposite column or pier.
Supply plenty of wire rope, cable clips, shackles, and perhaps clamps & slings. Guy
tightening equipment is generally not needed, but a pair of cable grabs for the guyline
cable size will come in handy. Guys may also be required on the hip courses.
Compression frames are a substitute for outside guylines. They are used primarily when
the site does not permit or provide enough space for temporary equator course guylines
outside the sphere foundation area. What constitutes enough space will depend on the
diameter and weight of the sphere as well as the winds to be considered. In most cases
a clear area equal to one sphere height beyond the foundation piers for 360 degrees
around the sphere will permit guying of the equator course. The guyline slope should
not be steeper than 45 degrees.
When compression frames are needed, contact Corporate Construction Technology for
assistance. Three frames are required. Two go on the first assembly erected and one
on the second. After that, the inside one is jumped ahead to the next assembly or plate
to be erected. Compression frames require extra material and field fabrication, as they
are custom designed for the diameter, thickness, and height of each sphere. Reuse is
possible if not probable. See Part 2 paragraph 2.6 and Fig. 2-7.
1.14 Pipe supports for upper and lower courses

On spheres with an unbalanced equator course, the lower end may tend to sag due to
it’s own weight. This only occurs on standard sizes 60’-6 to 72’-6 in diameter which are
6 course layouts. The modified expanded cube layout shown in Fig. 1-1 is a 6 course
sphere (2 three-plate heads, 2 four-plate side courses, 1 equator, and 1 upper hip).
Because of the unbalance, the lower ends of the plates tend to droop down. The open
ends of the course need to be supported as the plates or assemblies are erected. The
best way to do this is with a 3 or 4 inch pipe acting as a column to prop up the plate -----
unless you are using compression frames, in which case the frame will automatically
take care of the problem. Three pipe columns will do the job. See Part 2 Fig. 2-9 for
similar support systems on lower hips.
A seven-course sphere (76’ to 91’-6 diameters) will have a lower and upper hip course
and a balanced equator course. In this case the lower hip assemblies tend to droop and
must be supported. Pipe or compression frames may be used, but the more common
method is to guy the plate back to the top of the equator course on the opposite side.
Provide three sets of guys with screw clamps on both ends to connect to. See Part 2
paragraph 2.7.
Upper hip courses (all spheres 60’-6 and above) may be guyed if the site conditions
allow and the loads are not excessive. The guys must prevent the plates or assemblies
from rotating toward the center and need to hold the plates up. If the plate is allowed to
sag, it will need to be lifted with key plates, which may be time consuming. The pipe
support systems described in Part 2 paragraph 2.9 provide a more effective support
system.
1.15 Post Weld Heat Treatment
ASME Section VIII requires PWHT for P1 carbon steel plate thickness over 1¼ inches,
except that above 1¼, to 1½ inches maximum, 200° F continuous preheat may be
substituted for PWHT. When field PWHT is required (by Code or contract), the
procedure will be written by Corporate Welding (CWT). The CS must work with the local
Welding Department to plan the equipment, the material and fuel, and the schedule time
needed. Do not overlook the fact that all the outside surfaces of the sphere must be
accessible for installation and removal of the insulation. See paragraph 1.5 F above.
Column jacking plates will be billed by Engineering, but the CS must provide the jacks.
1.16 Authorized Inspection Requirement
CB&I has an agreement with The Hartford Steam Boiler Inspection and Insurance
Company (Hartford) to provide inspection services for pressure vessel work on all work
in the USA and at most foreign locations when the vessel is ASME stamped. CB&I
Engineering will complete a form GO 241 Notification for Inspection Services with
copies to the Shop and Construction (Project Manager and Welding Manager). It is the
Project Managers responsibility to arrange for the inspection with Hartford. See
Standard 493-1 for paperwork requirements and other details.
1.17 Pressure Testing

Spheres may be hydrostatic, hydropneumatic, or even pneumatic pressure tested

depending on the product weight and the design parameters applied. In most cases the
test will be hydrostatic.
The Construction Supervisor must plan the test. Blind flanges, bolts, nuts, and gaskets
must be ordered for each nozzle. Connections for the test pump, pressure gages, and
the fill hose or pipe are installed in bottom nozzles if available. Two pressure hoses are
required, one for the test pump and one for the gages. Air hose may be used to 100
psig, but do not use crows foot connections. For higher pressures, “Commander" brand
hose by Thermoid, (1/2" ID Standard Duty, 1500 PSI Max. working pressure hose with
1/2" NPT fittings) is recommended (RBS 155-17-1-2). A test manifold with two dial
gages and one recorder is the standard set up. All gages and the recorder must be
calibrated. The maximum pressure of the gages must be in the range of 1.5 to 4 times
the test pressure.
A. Pressure and vacuum relief vents are not usually required for test. But, do use
a pressure relief if the test pressure at the top is less than 15 psig and use a vacuum
relief if performing an external pressure (vacuum) test on a vessel designed for anything
less than a full vacuum. If no vacuum relief is installed, a nozzle on top (at least the size
of the water outlet) must be opened after lowering the pressure to near zero at the top
and before withdrawing water.
B. In most cases test water is furnished by the customer. Occasionally, the

customer will pipe and pump the water into the sphere. If CB&I is responsible for filling,
the CS must plan the connection to the water source and the pipe or hose as well as
valves and fittings to hook up to the sphere. The time required to fill the sphere will
depend on the hose or pipe (size, length, fittings, etc.) and the pressure while filling.
The following formula is offered as a rough method to calculate the time required to fill
the sphere with test water.
2.3P – E = V² (12.4 f/d) or V = sq. root of [(2.3P – E) ÷ (12.4 f/d)]
V = the velocity of the flow in ft/sec,

P = pressure at the source in psig,
E = the elevation change from the line connection to the horizontal centerline of
the sphere in feet,
f = the friction factor (use 0.03 for clean hard pipe and 0.06 for hose or rough
pipe),
d = the pipe or hose diameter IN FEET.
Solve for the velocity, then multiply by the area of the pipe in square feet (π d²/4) to get
cubic feet per second. Multiply by 3600 to get cubic feet per hour. Divide that number
into the volume of the sphere (πD3/6) for an approximation of the hours to fill.
Note that the 2.3 constant converts the pressure to feet of head and that 2.3P must be
more than the head to the top flange of the sphere (E + radius + nozzle height). The
12.4 accounts for 300 feet of pipe or hose with two high friction loss valves between the
source and the sphere. 600 feet would make the 12.4 about 17.
This formula attempts to make a complex problem simple and has not been tested as of
this writing. Your feedback to CCT as to its accuracy will be appreciated.
C. Pressurizing the sphere for hydrostatic test can take many many hours if
not planned properly. First, over-flow every nozzle on top to remove all the air, then use
the line pressure on the fill line to obtain whatever pressure is available there. Control
the rate of pressurization with a remote valve. Hold it down to a rate of about 10 percent
of the test pressure per minute.
The test pump or pressurization method needs to be chosen based on pressure and
what volume of water will be required to 1) stretch the sphere shell plates to the strain
level at test pressure and 2) account for the compressibility of water. The increase in
volume due to elastic strain (stretch) of the steel can be estimated as between 0.25%
and 0.35%. The higher strength the material (design stress) the larger the increase. Div
II spheres will be over 0.3% and Div I spheres in the 0.27% range. The water
compression will be about 1/300,000 of the volume per psi of test pressure. That
equates to 0.1% of the sphere volume for a 300 psig test.
Example: 69’ diameter sphere; Div I; Test Pressure = 196 pig

Volume = π D3 ÷ 6 = 172,007 cubic feet
Volume of water required to raise the pressure to 196 psig = A + B
A = 0.0027 x 172,007 = 464.4 cubic feet from stretching
B = 196 / 300,000 x 172,007 = 112.4 cubic feet from compression
Volume required = 576.8 cubic feet or 4,315 gallons or 16,333 liters
The point is don’t send a high-pressure low volume paint pump and expect to test this
sphere in a few hours. A 45-1 paint pump will only deliver 3.3 gpm -- 21.8 hours to
pump up this sphere. Manifolding paint pumps is a realistic alternate.
D. Test pumps available from CB&I warehouses may vary, but the common ones in
the USA are positive displacement air operated Pinnacle models PDQS 1400, PDQC
2500, and PDQC 500. The numbers are the maximum pressure available using 100 psi
air to operate the pump. We are unable to secure pump curves, but the rates may be
estimated on the low side by assuming a straight line between the maximum flow at
zero back pressure and zero flow at the maximum pressure rating.
The estimated curves in Fig. 1-2 illustrate very well that the PDQS 1400 will give the
best result on test over about 100 psi gage reading.

15
14
PCQC 500
12
10 PDQS 1400
GALLONS
PER 8
MINUTE
6 PDQC 2500
4
2
200 500 800 1000 1200 1400 1750 2000 2500

PSI BACK PRESSURE
Fig. 1-2 Straight line estimate of test pump flow rates
The rental rate on the PDQS 1400 is about $60/wk compared to $14/wk on the PDQC
500 (1998 rates). The PDQC 2500 is only rated at 5.0 gpm at zero pressure and rents
for about $60.
Equipment rental companies sometimes have industrial or oil field pumps that can be
used to test spheres.
E. The time required to pump air into a sphere for a pneumatic test may be estimated
as follows:
1) Calculate the volume (V) of the sphere or the free space above the water for a
hydro-pneumatic test.
2) Find the volume of air (Vt ) required to raise the vessel to test pressure. For
every 14.7 psi (1 atmosphere) of test pressure you will need 1 volume (V) of air added
to the vessel.
Vt = V (P) ÷ 14.7 psi
Where P = the test pressure in psig at the top.
3) Determine the total time (T) required in minutes by dividing the rated capacity
of the compressor(s) (C) in cfm into the volume of air required (Vt). Use a 75%
efficiency for the compressor(s) assuming at least a 2” diameter bull hose size. The
output curve on a screw compressor shows very little reduction in output as the
pressure increases (< 5%) so this factor is ignored or covered by the 0.75 efficiency.
T = Vt ÷ 0.75C
Example calculation on next page.

Example calculation:
48’ diameter sphere
Full pneumatic test to 80 psig.
Volume V of the sphere = π D3 ÷ 6 = 57,906 cubic feet
Volume Vt required to raise to 80 psig = 57,906 (80) ÷ 14.7 psi = 315,135 cu ft
Compressors: Say two 280 cfm Sullairs = 560 cfm
Time in minutes = 315,135 ÷ 0.75 (560) = 750 minutes or 12 hrs 30 min.
You might want to look for more compressor capacity or consider pumping it up to near
test pressure over night with just a couple of people on site.
Pneumatic test may require pressures higher than the capability of our construction
(100 psi) or paint (150 psi) compressors. Rental of higher pressure compressors is one
option. Another is the use of high pressure or liquid nitrogen. Do not use oxygen or
combustible gases for testing. If nitrogen is used, it must be warmed before entering the
sphere and the hazards involved require the involvement of the District Safety
Department. A purge with forced fresh air is required before personnel enter the sphere
and the existence of 19.5 to 22.0 % oxygen must be confirmed with a calibrated meter.
1.18 Column fire proofing
Most spheres will require fire proofing on the columns as specified by the customer.
Typically, the erection crew will install the clips and the top cover for the fire proofing. A
subcontractor will furnish and install the wire mesh that holds the fire proofing material
on the column. The subcontractor may hand trowel the concrete or spray it on as Gunite
or equivalent. The CS or Project Manager will subcontract the work and administer the
subcontract within the company subcontracting policy.

SPHERE CONSTRUCTION
2.1 Check the foundation
Spheres are built on pier foundations, which, in most cases, are subject to individual
settlement. It is very important that an accurate level survey be made and recorded
before the erection loads are applied to the piers. Elevation is also important. Tie the
level survey to a benchmark with a known elevation if possible. If one is not known, use
a convenient fixed point outside the foundation area. There is no standard CB&I form for
sphere level readings.
The level survey should be made with the instrument set up near the center of the
sphere. This will minimize the effect of any inaccuracy in the instrument. See Manual 13
Part 1 for a procedure for checking the instrument. Setting the instrument near equal
distance from the benchmark and the reference pier of the foundation will enhance the
accuracy of the benchmark reading.
The anchor bolt locations also need to be checked. The way we do this is to check the
radius to the anchor bolts and the chords between centers of the piers. The center of
the pier is defined as the center of the anchor bolt layout. The chords will be found on a
contract drawing. If any chord is off more than ¼” the Superintendent should advise the
Construction Supervisor the foundation is out of tolerance. The CS will need to pursue it
with Engineering and the customer if CB&I is not responsible for the foundation.
Fig. 2-1 Checking pier and anchor bolt locations
Also check the spacing between anchor bolts and the condition of the threads. Clean
and repair as required. If an anchor bolt is out of plumb to the extent that it will not fit the
base plate, try tapping the bolt with an 8 # hammer using two nuts jammed together
near the top. This is not hard hammering. If that does not work, contact Engineering for
a straightening procedure to avoid cracking the concrete.

SPHERE CONSTRUCTION
2.2 Shim the piers
Four, or more, shim stacks (per the drawings) are placed under each column to support
the sphere during construction until grout is placed. The grout is required prior to filling
the sphere with water for test. Shim the highest pier a minimum of one inch unless the
drawings call for more. After the shim stacks are in place, it is a good idea to tack or
tape them together to prevent separation as the columns are erected.
Fig. 2-2 Shimming under the columns
2.3 Check post plates and columns for length
As with all tanks and vessels, it is very important that the base course (in this case the
equators) be level. Before setting the columns on the shims, measure each of the post
plates and the columns as shown in Fig. 2-3.
If there is any variation in the lengths, try to combine the short post plate with the long
column etc. to make them all equal. If there is still variation, it must be accounted for by
adjusting the shim stacks on a particular pier to which the errant column and post plate
will be assigned. There may be more than one column involved. Number the piers,
columns, and post plates as required to get matched sets together.
A level survey of the top of the equator ring after the plates are erected is suggested if
any unusual difficulty is had in fitting the equator vertical joints.

SPHERE CONSTRUCTION
Fig. 2-3 Field measurement of post plates and columns to match sets
2.4 Field fabrication of post plates
Column stubs are often field installed to reduce ocean freight volume or when only one
post plate can be shipped per truck and the weight is light. The shop will layout the
column stub and punch mark match points on both the plate and the post as shown in
Fig. 2-4. Actual trial fitting and matching of each post / plate combination in the shop is
recommended when feasible. It is very critical that the field fit-up is done with precision
and that the weld shrinkage is controlled. The field procedure should be:
1) Set the equator plate on a level support system and hold the chord from the
drawings on both sides. The middle will need to be supported to avoid
deformation due to the plate weight. If necessary, pull the chords with a come-
along. Verify the shape with a six-foot sweep board.
2) Locate the column stub that was matched to the plate by the shop. Position the
stub on the plate using the punch marks made by the shop.
3) Weld temporary bracing angles as shown in Fig. 2-4 while holding the stub level
and dimensions AB & CD equal. This assures the column stub is square with the
plate. Tack the stub to the plate generously (1” on 6”).
4) The bevel for the full penetration weld of the stub to the plate must be gouged
after fit-up. Gouge 8 or 10 inches, then weld the first pass before gouging farther.
Complete the welding keeping the two sides of the stub balanced within a foot or
two of welding. Remove the temporary braces before erecting.

SPHERE CONSTRUCTION
Fig. 2-4 Field fabrication of post plate assemblies
2.5 Erect and weld columns
A. The lower columns should be erected with the scaffold brackets in place. Notice
in Part 3 that the elevation of the column scaffold is always given from the equator of
the sphere. This is because the scaffold is needed to weld the girth at the bottom of the
equator (in many cases) and Engineering varies the column splice elevation to suit
material sizes and other variables. There should always be a minimum of 12 inches
SPHERE CONSTRUCTION
clear between the column splice and the sphere shell. Be sure to use 2A23 column
bracket straps oriented as presented in Part 3. Also note that Extra Wide standard
brackets are often required for some of the bracket locations on the columns.
If practical, it is suggested that the column bracket straps be installed in the shop where
it can be conveniently done at the same time as the erection nuts and guide lugs for the
column splice.
B. Rig the column with two chokers so it will hang near plumb or, if Engineering
provides the guide lugs with shackle holes, rig with 3 equal length slings. Do not cut
holes in the lugs, as they are not designed for lifting if holes are not provided. As the
column is tipped up from horizontal, install the brackets. The boards may be bundled
and set on each column after it is in place. Carefully set the column on the anchor bolts
to avoid damage to the threads. Tighten the nuts hand tight only.
Be sure to match the columns to the piers (shim stacks adjusted for column & post plate
combination length) as described in 2.3.
For PWHT spheres be sure to install the jacking plates (greased) on the piers before
setting the columns.
A bracket strap (tank erection) ladder is suggested on one column for access to the
column scaffold. Use a scaffold trap door, J bolted to the brackets. A vertical wooden or
fiberglass ladder extending above the scaffold handline is also acceptable when
properly secured.
C. Column bracing will be flat plate butt-welded to the wing plates at the base of the
columns and in the column stubs on the equator plates. It is advantageous to leave the
bracing off the sphere until the scaffold between columns can be removed to eliminate
the interference between the boards and the bracing. The bracing is not required until
during test in most cases. Engineering Assigned will define, in the test instructions,
when the final welds are to be made on the lower end of the braces.
2.6 Erect equator course
The equator course may be erected in single plates or in two or three plate ground
assemblies. Ground assemblies should be planned so the leading plate of each
assembly erected is a post plate (no cantilevered plates). The first plate erected will
be a single post plate (or a 3-plate assembly). Erection of individual plates will best
describe the methods.
A. Each plate or assembly should be “dressed” to the maximum extent possible on

the ground. This means all the blank nuts, bracket straps, key plates, bull pins,
brackets, boards, handline, etc. should go on the plate / assembly to the extent
possible. For single plates the boards will have to wait. For expanded cube layouts the
bracket strap layout and orientation is difficult, but if you keep in mind that the verts are
always plumb, it can be done satisfactorily. Weight adders can be estimated as:
Key plate 18# 4 bull pins 10# Adjustable bracket 35# Bracket arm 11#

SPHERE CONSTRUCTION
EW adjustable 74# 100’ 3/8 cable 26# Standard bracket 33# 12’ board 80#
On both sides of each post plate or the leading end of each assembly (based on the
erection direction) weld a landing angle as shown in Fig. 2-5.
Fig. 2-5 Landing angles for equators and lower hip course
B. Erection rigging may be done with hitch lugs or with clamps on the top edge. On
spheres with unbalanced equators (standard sizes 60’-6 to 72’-6’) clamps should be
used. If the equators are balanced (all other sizes), hitch lugs located over the center of
gravity will make the plate hang with the stub plumb. Hitch lugs are necessary on the
smaller spheres (up to 54’-9), but on the larger balanced equator spheres (76’ and up),
clamps will do because they will not throw the stub much out of plumb. See Fig. 2-6.
See Construction Manual 62 for sling, shackle, and hitch lug or clamp selection. The
Renfroe SCP in the 6 or 10 ton size is suggested if available. Two taglines should be
used on all sphere plate lifts.
C. Set the post plate on the selected column and make the three 1” bolts. Tighten
the bolts and secure the plate with guys or compression frames and guys before cutting
the rig loose. Guys may be attached to dead men, anchor screws, other structures,
heavy equipment, etc. Tighten wire rope clips on guys with a torque wrench.
See Fig. 2-7 for an explanation of compression frames. The frames are always contract
specific, usually field fabricated, and designs are available from Construction
Technology in Houston. In most cases outside guys are preferred due to cost, but when
the site is very restricted, the frames are an effective alternative.
Guylines or compression frames should be set so the equator plates lean out slightly.
This will make it much easier to get the intermediate plates in place between two post
plates. The key plates will pull the plates plumb. Use this same logic throughout sphere
erection. Let the key plates pull the plates in place after setting the plate with a gap.

SPHERE CONSTRUCTION
Fig. 2-6 Use of hitch lugs vs. clamps to hang equator plates on various diameters.
Guy the first two post plates set, then fill in the intermediate plate. Land the intermediate
on the landing angles (Fig. 2-4) and make the key plates from the bottom up as the
plate settles in place. Keep an eye on the guylines. If they get tight, slack off on them.
When all the key plates are made, flush the top with the proper gap (as measured by
the punch marks – see 2.13 A). Flush the bottom with the right gap (see paragraph 2.13
A), then fit the rest of the vert. Never start on one end and fit to the other. Welding may
begin as soon as proper scaffolding is available.
The equator courses for 60’-6 through 72’-6 diameter spheres are unbalanced with most
of the plate being below the column. These plates tend to sag due to their own weight
and need to be supported temporarily as they are erected. A pipe support is suggested.
See Fig. 2-9 on page 10 for a similar support situation on lower hip course plates.
D. Erect the remainder of the equator course following the same procedure. As soon
as three post plates and two intermediates are erected, the guys (and compression
frames if used) on the middle post plate may be removed and used on the fourth post
plate. Three guys as shown in Fig. 2-7, or two guys and a compression frame, must be
in place on all open ends when an incomplete equator course is left overnight. Add guys
if high winds or thunder storms are expected.
Wedges may be used under the columns to help tip a post plate out slightly, but be sure
to use a heavy plate (such as a welders test plate) under the wedge for bearing.
Otherwise, the concrete may fail in shear. This procedure is especially helpful on the
last equator intermediate plate. Remove the wedges as the verts are fit, then make sure
the top of the equator is still level.
E. The column splices may be fit and welded, only after one side of all the equator
verts are welded. The column splices must be welded before test. If the column splices
are not welded before other courses of the sphere are erected, leave the bolts tight,

SPHERE CONSTRUCTION
weld the guide lugs on one side, and put 2-inch tacks on 8 inch centers in each space
between bolt and lug. Any lug or bolt may be replaced with a 2-inch tack.
Fig. 2-7 Equator post plates with guys outside or compression frames inside to
resist external wind force. Inside guys resist wind from inside in both cases.
Shown for 54’-9 sphere.

SPHERE CONSTRUCTION
2.7 Erect lower hip courses
Standard size spheres from 76’ to 91’-6 diameter have a lower hip course. Above 91’-6,
two lower hip courses will be required. A second hip course is erected exactly like the
first and will not be specifically covered by the manual. All hip courses should be ground
assembled in 3 or even 4 plate assemblies if the crane will handle the weight.
Rig the lifts as shown in Fig. 2-8. Before erecting, dress each assembly to the maximum
extent possible with key plates, bull pins, and scaffolding.
Fig. 2-8 Rigging of lower hip course assembly for erection
A. Layout all the verts between hip course ground assemblies on bottom edge of
the equators. Erect the first assembly on the starting point, catching the upper edge with
key plates on about 2’-6 centers. Others should be hung to the vert locations (like 1/3
points on a flat bottom tank).
The lower end must be supported, either with guylines back to the top of the equators
on the opposite side, with timber shoring, or a vertical pipe or pipes on the bottom edge.
See Fig. 2-9. Guylines are the preferred and most economical method. Use two on the
first assembly and one on those following. Jump the middle guy to the next assembly.
The Construction Supervisor should furnish the theoretical height of the bottom of the
hip course above the column base. Set the assembly a little low and let the key plates
lift it in to shape.
Weld a large finger bar across the girth seam between each pair of key plates before
cutting the crane loose from the assembly. See Fig. 2-10.
B. Fitting and welding of the lower hip verts may begin as the plates are erected.
Girth fitting should begin only after it has been established that the circle will close or

SPHERE CONSTRUCTION
after all the plates are erected. Girth and vert welding may be simultaneous as long as
the girth weld does not cross an unwelded vert.
Fig. 2-9 Support systems for lower hip course – shown for 91’-6 diameter
Fig. 2-10 Large finger bar required between pairs of key plates and near leading
edge before releasing the crane on lower hip to equator girth seam.

SPHERE CONSTRUCTION
2.8 Erect the bottom head plates (7-piece head includes 4 “side plates”)
Bottom head plate erection (with the exception of the center plate) is done before
proceeding with the plates above the equator course.
A. For seven piece heads, layout the 4 verts on the course above and try to hang the
plates to the marks.
Fig. 2-11 Rigging of the four side plates on a 7 piece bottom head
These 4 around courses typically come out long or short due to the number of verts
(shrinking or not shrinking) in the course above. If necessary, jam the verts at the top
and maintain the gap at the bottom. If it becomes necessary to trim, trim all 4 verts but -
DO NOT TRIM ANYTHING OFF THE LOWER CORNER. If the corners are trimmed the
3 head plates will not fit in the hole. Welding of the side plate verts should not start until
all four are fit. The side plate girth to the course above should not be fit until the four
verts are welded on one side and girth welding should not cross an incomplete vert.
B. Erect the two outside pieces of the three-piece center head. Be sure to leave room
for the center plate, which will be erected just prior to closing the top head in most
cases. Leaving the center plate out provides ventilation, light, and makes it much easier
to remove the scaffolding. Support the center of each plate and install a double handline
and toe boards (to stop dropped projectiles) around the opening.
The two bottom head plates may be welded to the four side plates, but leave a foot or
two unwelded at the center plate joint, if the center plate is to be erected later.
C. The three piece bottom head may also be ground assembled if the crane can
handle flipping and setting the size and weight of the assembly. Set the assembly under
the sphere before erecting the top head side plates. Leaving the bottom open until the
scaffolds are removed from the inside will save bullgang time but may also affect the
schedule.
A two piece ground assembly with one of the off center plates being left out until the last
phase of the job is another alternative.

SPHERE CONSTRUCTION
Fig. 2-12 Erection of the bottom head – shown for 54’-9 diameter
2.9 Erect upper hip courses
A. Before the upper hip course erection begins the inspection scaffold should be set
in the bottom of the sphere – because it is always larger than the opening remaining.
The alternative is to assemble the scaffold in the bottom of the sphere.
B. Upper hip courses occur on all standard spheres 60’-6 diameter and above. Two
upper hip courses are not seen on standard sizes, but will occur above the maximum
standard diameter of 91’-6.
Hip courses, whether upper or lower, are often detailed with alternating plate shapes
(pie – rectangular) ---- but, only if the plates are short enough to get two sharply tapered
plates out of one rectangular (40’ maximum order length). The layout consists of one
rectangular shaped plate followed by a “pie” shape, etc. None of the seams are radial ---
instead, the centerline of every plate is radial. This fact only becomes a problem when
laying out scaffold brackets (if you square the strap with the side of the plate it will not
be horizontal).
C. Ground assemble upper hip courses to the maximum extent possible, within the
lifting capacity and reach of the crane. Dress each assembly with key plates, bull pins,
brackets, boards, and handline. See paragraph 2.6 A for weights of these items. Upper
hip courses are fit from the outside, so be sure to get all outside scaffold in place on the
ground. The inside scaffold will be vert boards in most cases.

SPHERE CONSTRUCTION
D. Rig the assemblies to hang near level (having the top end an inch or two high is
ideal). Two hitch lugs slightly above the center of gravity with a third leg connected to a
lug on the bottom center (for leveling with a come-along) is the better arrangement. If
rigged with two clamps on the top edge and a lug near the bottom, the cable required to
level the load will carry more than half the weight because of the distance the clamps
will be from the C.G.
E. Once erected, the upper hip course assemblies must the supported on the upper
end, either with guy lines to the outside or pipe supports on the inside. A mast with
suspension guys is a third option that is usually considered only on very large spheres.
Guy lines work OK on thin plate, but since the upper hip only occurs at 60’-6 diameter
and above, the loads are always substantial and the guys need to be designed by
Construction Technology or other qualified persons. Pipe supports are recommended
because they can hold the tops of the assemblies to the exact elevation desired. With
guylines the tops tend to be low and this causes problems with plates overlapping
making it difficult to install the key plates.
Figures 2-13 and 2-14 show two methods for using pipe supports. In most cases, the
fixed length supports should be used to avoid the guylines and all the lugs required for
the guys. Fixed length supports may be bolted to the assemblies on the ground if the
crane has enough boom to lift the support over the equator. If not, place the pipe in the
sphere with the top extending a foot or so over the top of the equator. Bolt the pipe to
the plate as the assembly comes up the side.
Construction Technology will provide pipe support designs, at the CS request, for any
size and weight sphere, in either the fixed length or guyed method. For very large non-
standard spheres, the supports may require trusses due to the length.
F. Before starting to erect, layout all the verts between assemblies (where they fall on
the top edge of the equator course). Try to hang each assembly to the layout point --- to
avoid problems getting the last one in. Erect the assemblies on keyhole shims on 3 to 4
foot centers. Key plate the girth seam on about 2’-6 centers and weld a minimum of 3
finger bars across the girth (and install the supports or guylines per the plan) before
cutting the crane loose. The vertical seams should have all key plates in place (and a
support pipe or guy on the leading edge) before releasing the rig.
See paragraph 2.13 for fitting and welding procedures.
2.10 Erection and welding of column bracing
The time to erect the column bracing is when the equator verts and the girth seam
accessed from the column scaffold are accepted so the column to column boards can
be removed. The bracing must be installed before test, but the lower ends are not to be
final fit and welded until a predetermined amount of water is in the sphere per the test
instructions. This procedure prevents the bracing from buckling due to product load
during operation.

SPHERE CONSTRUCTION
Fig. 2-13 Use of fixed length pipe supports on upper hip course
Shown for a 60’-6 sphere.

SPHERE CONSTRUCTION
Fig. 2-14 Use of guyed pipe supports on upper hip course

Shown for a 60’-6 diameter sphere

SPHERE CONSTRUCTION
2.11 Erect top head plates
A. Standard spheres 40’-6 diameter and above have seven piece heads. In a few
cases you might see a six-piece head (4 side plates and 2 centers). Before erecting the
head plates, the inspection scaffold must be accounted for.
Spheres that do not have an upper hip course (54’-9 or less), use a bracket and board
scaffold to weld the 4 side plates to the equators. On these diameters, the inspection
scaffold is only used for the three head plates in the center and is attached to the 4 side
plates. The inspection scaffold must be in the sphere (on the bottom) before the 4 side
plates are erected.
For larger spheres, 60’-6 and above, the inspection scaffold is larger than the opening
at the top of the upper hip course and will have been set in the bottom before erecting
the hip. The inspection scaffold should be lifted and attached to the upper hip course
before erecting the 4 side plates of the top head.
B. For seven piece heads, layout the 4 verts on the course below and erect the plates
to the marks. These 4 around courses typically come out long or short due to the
number of verts (shrinking or not shrinking) in the course below. If necessary, jam or
spread the verts at the bottom and maintain the proper gap at the top. If it becomes
necessary to trim, trim all 4 verts, but - DO NOT TRIM ANYTHING OFF THE UPPER
CORNER. If the corners are trimmed the 3 head plates will not fit in the opening. Also,
do not trim without consulting with the Construction Supervisor.
Erect the side plates on shims. Key plate the girth on about 2’-6 centers and weld a
finger bar between each pair of key plates (and one on each end) before releasing the
crane. No supports should be required.
C. The inspection scaffold superstructure (see Part 3 paragraph 3.12) must be in

place but with board positions limited as defined by Part 3 paragraph 3.12 D, before
erecting the three top head rectangular plates. Large finger bars may be used on the
individual head plate edges as stops to prevent the plate from going inside the opening.
Key plates on about 2’-6 centers with a finger bar between each pair are required before
cutting the rig loose from each plate.
The center head plate should be left off as long as possible without holding up the
schedule. Once the center plate is erected, ventilation becomes very important. See
Part 1 paragraph 1.7 for ventilation options. Hearing protection is mandatory when
working in the sphere with an air raise fan running.
D. While it is not the recommended method, it is possible, on 7 piece heads, to erect

the top center head plate/s with a crane that will not reach the final location within it’s
capacity. The crane must be able to set the plate on top, after which it is pulled into
position with come-alongs. Rigging to support and move the plate, as well as angle or
heavy plate stops to catch the plate as it slips into the opening, should be designed by
Corporate Construction Technology. Stops should also be provided to prevent the
possibility of the plate moving too far in any direction.

SPHERE CONSTRUCTION
2.12 Ground assemblies, methods, turning, and rigging
A. Two, three, and occasionally four plate ground assemblies are often used on
equator courses, hip courses, and head plates. Before committing to a ground assembly
plan, the availability of a crane that can handle the lifts within rated capacity and access
to position the crane for the lifts must be assured.
B. It is recommended that sphere ground assemblies not be turned over to weld the
first side. Assemble with the first side bevel up, fit, then remove the finger bars and key
plates just in front of the first fill pass welding. On thin material (1/2” or less) replace the
key plates after the welder clears the area (or weld through the key plates).
If not fit from the first side to weld, the ground assemblies will require an extra turn
because the first side welded must always finish on the top because the rigging goes on
that side. Also, if not fit from the first side to weld, the assemblies must be turned with
just key plates and finger bars, which requires that the assembly be rigged so the
seams are vertical when the assembly is lifted, and that large finger bars be welded
across the seams to hold it together. Use large finger bars on 4’ centers for single bevel
tacked in the seam and 6’ for joints fit with small finger bars.
C. Ground assemblies must be supported as they are fit and welded so that the
shape approximates the theoretical radius, chords, and versines, i.e. the spherical
shape. For hip courses this is easily accomplished by using the first assembly as a
template for the others. Chord dimensions needed may be requested from Engineering
if not on the drawings.
Plate templates can not be used on equator course assemblies, because of the column
stubs on every other plate. Each assembly must be individually shaped using cribbing
or a rolled angle template. Cribbing is the norm on single spheres (see Fig. 2-15), but
with multiple spheres of the same size an angle template may be justified ---- especially
if preheat is required. The preheat equipment can be mounted on the template saving
setup cost for each assembly. Construction Technology can help with template designs.
Plates and assemblies must be rigged to lay into or lift out of the angle template without
damaging the template. Four screw type plate clamps and long slings are suggested for
removing the assemblies.
D. To turn an assembly, put two clamps on one of the long sides at about the third
points (see paragraph B. above if the first side is not welded). Lift vertical then set the
assembly down on crib stacks. Two stacks, side by side, in the middle should cause the
assembly to rotate to the shed water position without spinning to the side. A stack near
each end should cause rotation to the catch water position. Rotation should always be
away from the boom.
Crib the assembly to the approximate chord and versine before gouging and welding
the second side. For the shed water position, place one crib stack in the center with the
calculated versine as the approximate height. For the catch water position support all
four corners.

SPHERE CONSTRUCTION
Before turning an assembly for the last time, layout and weld the bracket straps on what
will be the under side. After turning, layout and weld all the erection nuts, bracket straps,
and hitch lugs required on the topside.
Fig. 2-15 Temporary support systems for ground assemblies
2.13 Fitting methods and equipment
A. Sphere plates are fabricated with a center punch mark in the corners. The punch
mark location is part of the template used to layout the burn lines in the shop. This
means the punch mark is more accurate than the actual edges of the plate. The punch
mark enables the fitter to fit to a theoretical shape making the overall shape of the
sphere closer to the desired shape and preventing wide gaps or laps on the last
assembly erected.
Hold the punch marks 3 inches plus the gap apart and hold them 1.5 inches from the
flush line of the plate ends. See Fig. 2-16.
B. When fitting the radial seams (verts and head plates), whether in the air or on the
ground, always flush both ends (use the punch marks) then fit to the center. This
procedure will make the verts fit easier and the girths will have less gaps to contend
with. Keyhole shims and the 2A44 shims shown in Fig. 2-18 will help align the plates.
Per ASME VIII the plates may be misaligned as much as one quarter the thickness with
1/8” maximum for thickness up to 2”. Above 2” the tolerance is one sixteenth the
thickness or 3/8” maximum. Misalignment is defined as the amount the thinner plate
overhangs the thicker plate.
C. Gaps in the air erected seems may be pulled with key plates, but a porta-power
type hydraulic jack with a field fabricated jacking box will save time. A typical jacking box
is shown in Fig. 2-17. Another possibility when pulling a gap on heavy plate is the
“double pull” system using a welded hinged key plate also shown in Fig. 2-17.

SPHERE CONSTRUCTION
Fig. 2-16 Use of corner center punch marks when fitting radial seams
Fig. 2-17 Special equipment used to pull gaps on heavy plate

SPHERE CONSTRUCTION
Fig. 2-18 CB&I standard heavy plate fit-up equipment

SPHERE CONSTRUCTION
C. Seams fit and welded on the sphere (in position) should be fit from the inside
below the equator (includes the full equator plate) and on the outside above the
equator. With the exception of balanced equator plates, this means fitting on the side to
be welded first. All plate bevels are detailed for the top side to weld first. See Part 1
paragraph 1.4 for an explanation and possible exceptions.
D. Double bevel joints must be fit with finger bars. Spacing should be about 2 feet.
Single bevel joints (up to 1” thickness) should be fit from the bevel side using finger bars
on 2 foot centers (as described in C. above), but may be fit without finger bars by
tacking in the root on the unbeveled side. Use finger bars if needed to keep the gap
open during the first pass welding or as an aid to prevent peaking. Larger finger bars
are especially effective when used as strong backs to prevent peaking.
Fig. 2-19 Fitting single bevel dished plates
E. All seams should have runoff tabs installed on both ends on the ground assemblies
and on the open end for in position joints. Large finger bars are suggested as strong
backs for thinner material (say ½” or less) or when needed.
Fig. 2-20 Use of runoff tabs and large finger bars as strong backs

SPHERE CONSTRUCTION
2.14 Welding procedures and sequence
A. The welding sequence should generally follow the plan below, however,
overlapping of the various weld task are expected. Girth seam welding may parallel
vertical welding as long as the girth weld does not cross an unwelded vert. Ignore steps
that do not apply for smaller spheres.
1. Weld ground assemblies.

2. Weld equator verts.
3. Weld column splices – must be before test.
4. Weld lower hip course verts.
5. Weld equator to lower hip girth.
6. Weld 4 side plate verts in bottom head.
7. Weld girth - bottom side plates to course above.
8. Weld 2 of 3 bottom head plates to 4 side plates (varies with erection).
9. Weld upper hip verts.
10. Weld equator to upper hip girth.
11. Weld 4 side plate verts in top head.
12. Weld girth – 4 top side plates to course below.
13. Weld 3 top head plates together (the square).
14. Weld top head plates to the 4 side plates.
15. Weld last plate in bottom head after scaffolding removed.
16. Weld top end of column bracing before test and bottom during test per the
Test Instructions.
B. Double bevel joints should be welded on the deeper bevel side first and may be fit
from the either side. When welded first from the same side as the fit-up, remove finger
bars and key plates just ahead of the first fill pass. Do Not leave gaps in the welding.
Use runoff tabs as described in Fig. 2-19.
C. Single bevel joints (1” and less in thickness) must be welded on the bevel side first
and may be fit on either side.
D. Use a back-step technique on the first pass welding when uphill welding tends to
draw the gap closed. Use about 2-foot steps. Start 2 feet down from the top. Taper the
start and finish of each step so they overlap about 1.5 inches -- to avoid cracking at the
tie in.
E. Back-gouging is to be done after the first side is fully welded. Gouge to sound
defect free metal before welding the second side.
F. Peening should not be done on the first or last passes in a joint. In general, light
peening or descaling may be done to aid in cleaning slag from the weld.

SPHERE CONSTRUCTION
G. Preheat per the contract Welding Procedure Specification. Local preheat for
temperatures below 50° F is always required to some extent. See paragraph 1.11 in
Part 1 of this manual for an explanation of the usual preheat requirements, but follow
the WPS.
No welding should be done when surfaces are wet from rain, snow or ice.
No welding should be done when rain or snow is falling on the surfaces being welded.
No welding should be done during high winds, unless the operator and the work are
adequately protected.
See the Contract Welding Procedure Specification for special welding requirements.
2.15 Clean up requirements on carbon steel sphere shells (inside and outside)
1. Remove all burrs and grind flush.
2. Remove all slag, weld splatter, and arc strikes.
3. Grind all pickups flush.
4. Welds and other projections are to be dressed with a grinder to remove sharp
edges.

SCAFFOLDING & ACCESS
3.0 Standard scaffolding rules
The CB&I rules for Tank Builder Scaffolds are covered in Red Book Std. 155-6-9-2, and
Part 7 of Construction Manual 13. Those rules apply to sphere scaffolds as well.
3.1 Brackets and handrail post used on spheres
The size and type of brackets used vary and must be taken from the scaffold layouts
provided. The various brackets and handrail post are depicted in Fig. 3-1. The brackets
are Standard, Extra Wide Standard, Adjustable and Extra Wide Adjustable. Dimensions
and weights (pounds) are approximate.
Fig. 3-1 Scaffold brackets and handrail post used on spheres

The numbers in parenthesis for the adjustable brackets refer to the bolting arrangement
to fit a desired slope and keep the boards near level. The first number is the hole count
from the end of the horizontal leg. The second number is the hole count from the end of
the diagonal leg. This convention is used to provide bolting information for each scaffold
level on the scaffold layout drawings.
3.2 Column bracket straps on small columns
Most scaffold layouts require 5 column straps 2A23 on each column. For columns 26
inches and less in diameter, the straps will interfere with each other due to the small
circumference. This is handled by putting 2 straps higher than the others. See Fig. 3-2.
Fig. 3-2 Column strap locations on small columns
3.3 Bracket straps for the inside of spheres < 60' diameter
Standard bracket straps 2A22 are designed for flat surfaces. For spheres under 60' in diameter
the versine in the bracket upright length causes the strap to fit tight on the bracket. The usual
cure is to beat the prongs on the bracket down so they will go in the strap, then beat the bracket
into the strap (in some cases), then beat the bracket out of the strap when plugging down. This
works OK down to about 50' in diameter. At that point a better solution is to use pole straps
2A24. The only difference is the depth of the loops. Standard straps are 1 ½" deep, while the
pole strap depth is 1 15/16". The CS will need to order the pole straps through Engineering.

3.4 Third handlines on column scaffolds
Scaffolds that have a bracket on each column and 1 or 2 on the shell between columns,
require a third handline to provide fall protection for the open spaces on both sides of
each column when the space exceeds 12 inches.
Fig. 3-3 Third handline required around columns
3.5 Arranging scaffold for welder comfort
The scaffold layout often requires two brackets on every other plate for outside scaffolds
and on the inside for many wide plate designs. When this occurs, the right-handed
welder’s comfort can be enhanced by arranging the brackets on 2 plate ground
assemblies as shown in Fig. 3-4.
Fig. 3-4 Scaffold bracket arrangement on two plate ground assembly

to not interfere with right-handed welder

3.6 Overhead protection and toe boards
Provide a minimum of one entryway with overhead protection from six feet outside the
outermost scaffold to six feet inside the column scaffold. Tube and clamp or other
manufactured scaffold covered with scaffold boards is the typical method used. The
remaining perimeter should be marked with barricade tape as on a cone roof tank.
Provide toe boards or equivalent around the opening in the bottom head to prevent a
dropped object from sliding down the sphere as a projectile into the open area. If the
bottom center plate is left out the toe boards should surround the entire opening.
3.7 Access path to top
A well-organized sphere job will have permanent access ladder paths, inside and outside
the sphere, established through out the job. The path will have secured ladders with the
3 foot extension above the next level (or a hand grab) and the offset between ladders will
be no more than a few sheets, so no one has to waste time hunting for the next ladder
on his way up or down. See paragraph 3.9 for suggested use of flexible ladders.
3.8 Rigid ladders
There are many spots on a sphere where the fitter, tacker, welder, chipper, and NDE
people are forced to work from a ladder. When they do so, they are required to secure
the ladder, wear a harness, and keep their lanyard hooked off to a secure point
whenever their buttocks are above the top handline of a scaffold. Do not hook off to a
wood or fiberglass ladder. Steel (CB&I), wood, and fiberglass ladders are the norm, but
in some cases a ramp made from two scaffold boards may come in handy. See Fig. 3-5.
Fig. 3-5 Ramp for use below the inspection scaffold in lieu of purchased ladder

3.9 Flexible ladders
Steel flexible ladders 2L1-20-A are recommended for the “permanent” access routes on
the inside below the equator and outside above the equator. These come in 10-ft.
sections, which may be interconnected providing a very secure ladder with plenty of foot
room. Flexible ladders (both wood and steel) are also used on the outside near the top
and inside near the bottom as portable ladders for general access for fitters, welders,
etc.
Fig. 3-6 Flexible steel ladder 2L1-20-A
Flexible wood “chicken ladders” may be fabricated on the jobsite per Fig. 3-7.
Fig. 3-7 Field fabricated flexible chicken ladder

3.10 Scaffold under the bottom head
Tube and clamp or other manufactured scaffolds are commonly used. The minimum
required is two, the length of the head plates (except on very low to the ground spheres).
100% RT and / or MT as well as PWHT insulation installation may warrant more
scaffolding, but keep in mind that the scaffolds are portable and may be moved.
3.11 Standard diameter sphere scaffold layouts
A. There are 20 standard diameters for spheres – from 22’-3 to 91’-6. Scaffold layouts
for all 20 in both standard (9’-8 max) and wide (11’-5 max) plate widths are provided in
the following 72 pages. The standard sizes are tabulated below. Note that four sizes
have only one design because the number of columns can’t be reduced. All the 4 and 6
column spheres are true expanded cube layouts (providing less scrap plate).
Standard sphere sizes with number of columns for standard and wide plate layouts
22’-3 25’-6 28’-0 30’-3 32’-0 35’-3 38’-0
4 col. 4 col. 5 / 4 col. 5 col. 6 / 5 col. 6 / 5 col. 6 col.
40’-6 43’-6 48’-0 51’-0 54’-9 60’-6 65’-0
7 / 6 col. 7 / 6 col. 8 / 7 col. 9 / 7 col. 9 / 8 col. 10 / 9 col. 11 / 9 col.
69’-0 72’-6 76’-0 81’-10 87’-0 91’-6
11 / 10 col 12/10 col 12 / 11 col 13 / 12 col 14 / 13 col 15 / 13 col
B. The plate layouts and number of columns are as provided by Engineering in April
1999. The wide plate designs reduce the number of columns to the minimum and
provide two plates per column in the equator course. Upper and lower hip courses use
wide plate also, but the 7 piece heads do not use wide plate. They remain the same as
with the standard 9’-8 maximum plate width designs. The reason for doing this is keep
all the θ angles (the angles between girth seams) the same, so the scaffold locations
and inspection scaffold sizes do not change.
C. The number of brackets and/or the board sizes usually do change with the wide
plate designs. Wide plate scaffold layouts follow each standard plate width layout and
are boldly and obviously noted as WIDE PLATE layouts.
D. Trap doors are recommended on all scaffold levels to provide safe access from
below without disrupting the scaffold by flipping the boards back. The Construction
Supervisor should requisition the doors and add the necessary brackets to the list. If
boards are flipped to gain access they must be repositioned to provide a complete
scaffold at all times.

E. The Construction Supervisor’s tool list must account for the fact that the board and
bracket quantities listed for each sphere provide for complete scaffolds inside and out
(no vert boards), but do not provide any extra for breakage or other uses. The CS must
also add boards for the inspection scaffold, the covered entryways, and any tube type
scaffolds used under the sphere. Board quantities for the inspection scaffolds are given
in Part 3 paragraph 3.12 with the inspection scaffold layouts.
F. Vert boards must not be used on the inside of the sphere unless they are on the
upper most course above the top girth seam scaffold. The full scaffolds are needed to
plug down. Vert boards may be used on the outside at any level (if there is no PWHT
required) with the understanding that some of the plugging down will be done from a
work platform of some type.
G. For non- standard size spheres contact Construction Technology in Houston for a
custom scaffold layout. These are done quickly and very accurately to scale in
Microstation, our CAD system.
The laps given for each scaffold level on the following standard layouts may be
extrapolated to larger diameters, but only if the number of plates and the angles
between the girth seams do not change. The angles to the head plate girths are given
on each of the standard layouts. If these two conditions are met, the lap “L” at the
standard diameter, which will meet the minimum 9” at the new diameter, can be
calculated from:
Where “p” is the decimal for the percent increase in diameter (0.025 for a 2.5% increase) and
“b” is the board length in feet. “L” will be the lap in inches at the standard diameter. Any lap on
the standard layout drawing smaller than this amount will not be acceptable at the new
diameter and will require either longer boards or more brackets.
The formula requires that all the scaffolds stay at the same azimuth / angle as for the standard
layout. This is accomplished by recalculating the arcs given on the layout by multiplying by 1
plus the decimal percentage increase in diameter (the divisor in the formula). The same logic
applies to the bracket spacing dimensions on the columns. They too must be increased.

22’-3 DIA STD DESIGN – SCAFFOLD LAYOUT

22’-3 DIA – STD DESIGN - COLUMN & TOP HEAD SCAFFOLDS


25’-6 DIA STD DESIGN – COLUMN & HEAD SCAFFOLDS



28’-0 DIA WIDE PLATE DESIGN - SCAFFOLD LAYOUT

28’-0 DIA WIDE PLATE DESIGN – COLUMN & HEAD SCAFFOLDS



32’ DIA STD DESIGN – SCAFFOLD LAYOUT

32’ DIA STD DESIGN – COLUMN & HEAD SCAFFOLDS

32’ DIA WIDE PLATE DESIGN – SCAFFOLD LAYOUT

32’ DIA WIDE PLATE DESIGN – COLUMN & HEAD SCAFFOLDS



35’-3 DIA WIDE PLATE DESIGN – SCAFFOLD LAYOUT



38’-0 DIA STD DESIGN –EQUIPMENT COUNT & COLUMN SCAFFOLD

40’-6DIA STD DESIGN – SCAFFOLD LAYOUT

40’-6 DIA STD DESIGN – EQUIPMENT COUNT & COLUMN SCAFFOLD


40’-6 DIA WIDE PLATE DESIGN – EQUIPMENT COUNT & COLUMN SCAFFOLD

43-6 DIA STD DESIGN – SCAFFOLD LAYOUT


















60’-6 DIM WIDE PLATE DESIGN – SCAFFOLD LAYOUT








69’0 DIA WIDE PLATE DESIGN – SCAFFOLD LAYOUT
















87’-0 WIDE PLATE DESIGN – SCAFFOLD LAYOUT

87’-0 WIDE PLATE DESIGN – EQUIPMENT COUNT & COLUMN SCAFFOLD





3.12 Inspection scaffolds – top head plates overhead scaffold
A. An inspection scaffold, suspended below the head plate opening, is required on

all standard sphere sizes 38’ and larger in diameter. Below 38’ access to the overhead
work on the top heads can be attained with a painters pick or boards spanning the
opening of the top board and bracket scaffold (as shown on the scaffold layouts). A
proper double handline system is always required.
Inspection scaffolds come in standard sizes to fit a range of head plate openings. The
standard inspection scaffold sizes are: 21’-6 (to 24’-6 opening), 30’-0 (to 33’), 34’-0 (to
37’), 42’-0 (to 41’), 45’-0 (to 44’-2), and 46’-0 (to 47’). Refer to the scaffold layout for
your diameter sphere to determine the size required. Bolted scaffolds may be reused
any number of times, but to date only the 34’ size has been engineered bolted.
A rarely used alternate is tube & clamp scaffold from the bottom of the sphere.
B. In all cases, the inspection scaffold elevation is too low for the welder to reach
part if not all the head plate joints. There are three methods suggested to increase the
elevation of the scaffold level. They are:
• Cover the inspection scaffold with scaffold boards and build tubular scaffolds on the
deck as required. Double the board thickness under the tubular legs.
• Use a superstructure with scaffold boards. Engineering will bill with this type of
super-structure with the inspection scaffold unless the Construction Supervisor’s
advises alternate scaffolding will be used.
• Use a superstructure with aluminum stages instead of boards. This superstructure

has fewer supports, thus less parts. Engineering bills only at CS request.
Fig. 3-8 Inspection scaffold without and with superstructure
There are a couple of sphere scaffolds in the Standard Construction Drawings – 2L18-3
and 2L19-3. These are octagonal shapes and may be 100% field fabricated, but they
are not designed for the loads imposed by the three methods of achieving elevation
above. Do not use them unless approved by Corporate Construction Technology.
For many years CB&I left the inspection scaffolds in the sphere when allowed by the
customer. Present policy is to remove all inspection scaffolds.

Engineering will bill the standard inspection

scaffold with superstructure (for boards) as
required for each sphere unless the
Construction Supervisor advises otherwise.
The superstructure method can only be

used if the main members of the inspection
scaffold can be aligned with the seams in
the head plates. If there is an interference
that will not allow the required orientation,
the superstructure method should not be
used.
Fig. 3-9 Orientation for superstucture
C. Handline must be installed on

all inspection scaffolds. The outer
supports will be provided with pigtails
to hold the handline. Interior
handlines should be attached to
bracket arms that are attached to the
structural with standard erection
equipment as depicted in Fig. 3-10.
Fig. 3-10 Handrail post attachment devices
D. Interior supports, which are positioned and attached to the plates above, after the
inspection scaffold is in place, are required on all the inspection scaffolds 30 feet and
larger in diameter. Do not place more than a few boards inside the radius of the interior
supports before they are welded to the scaffold and attached to the head plates. A few
boards will help install the supports.
On scaffolds with super-

structures, the interior supports
are welded extensions to super-
structure vertical members. This
permits the completion of the
superstructure before setting the
scaffold. Do not place but a few
boards inside the radius of the
supports before attaching the
extension to the vessel and the
scaffold. See Fig. 3-11.
Fig. 3-11 Interior supports with superstructure

E. Inspection scaffolds and

superstructure are generally located to
satisfy the requirements on Fig. 3-12;
however, specific elevations are defined
for the inspection scaffold for each
sphere size on the scaffold layout
drawings.
Engineering will bill superstructure

material in lengths to satisfy these
elevations plus 12”. Field adjust to suit
welders.
Fig. 3-12 Elevation of Inspection scaffold
F. Inspection scaffolds on spheres 81’-10 and larger
The head plate openings in the very large spheres (81’10 and larger) are wider than our
largest standard inspection scaffold, which is the 46 foot diameter. In order to avoid designing
a larger inspection scaffold, the support angles around the perimeter should be sloped or
battered as described by Fig. 3-13. The 81’-10, 87’-0, and 91’-6 standard diameters are all
done with the same 2 3/8 : 12 batter on the supports. See the individual size layouts for the
dimension from the support clip to the head plate girth seam.
Fig. 3-13 Circumferential support angles on 46’ diameter inspection scaffold

for spheres 81’-10, 87’-0, and 91’-6 in diameter.

G. Inspection scaffolds decked solid with boards
Boards required as shown Approximate weights
9 – 12 foot Steel only – 1200 lb.

14 – 10 foot Boards only – 3000 lb.
20 – 8 foot
Fig. 3-14 21’-6” INSPECTION SCAFFOLD 7A5-1 DECKED WITH BOARDS

Boards required Approximate weights

4 – 10 foot
4 – 8 foot
Fig. 3-15: 30 FOOT INSPECTION SCAFFOLD - 7A5-2 - DECKED WITH BOARDS


Fig. 3-16: 34’-0 INSPECTION SCAFFOLD – 7A5-3 – DECKED WITH BOARDS

Boards required to deck 46’ scaffold Approximate weights

as shown
(deduct 16 – 12’ boards for 42’ scaffold) Steel only – (42’ = 4600 lb.)
(45’ = 4900 lb.) (46’ = 4950 lb.)
26 – 14 foot Boards outside the interior support points
124 – 12 foot only: allow 9800 lb. for all sizes
10 – 10 foot
Fig. 3-17: 42’, 45’, AND 46’ DIAMETER INSPECTION SCAFFOLDS 7A5-4, 5, 6
DECKED WITH SCAFFOLD BOARDS

H. Inspection scaffolds with superstructures for boards

22 – 12 foot Boards on lower level only – 2550 lb.
Fig. 3-18: 30’ θ INSP. SCAFFOLD 7A5-2 WITH SUPERSTRUCTURE FOR BOARDS

Boards required as shown Approximate weight

4 – 10 foot Boards on lower level only – 2800 lb.
Fig. 3-19: 34’ θ INSP. SCAFFOLD 7A5-3 WITH SUPERSTRUCTURE FOR BOARDS

12 – 14 foot Steel only – (42’ - 5700 lb.)

58 – 12 foot (45’ - 6000 lb.) (46’ - 6056 lb.)
8 – 10 foot Boards only on 2 lower levels – 6000 lb.
Fig. 3-20: 42’, 45’, & 46’ DIAMETER INSPECTION SCAFFOLD 7A5-4, 5, & 6
WITH SUPERSTRUCTURE FOR USE WITH BOARDS

I. Inspection scaffolds with superstructure for aluminum stages
38 - 12 foot Steel only – 3200 lb.

2 – 24 foot aluminum stage Stages – 140 lb. each
Fig. 3-21 34’ DIAMETER INSPECTION SCAFFOLD 7A5-3 WITH SUPERSTRUCTURE

FOR USE WITH ALUMINUM STAGES

26 – 14 foot Steel only – (42’ - 5360 lb.)

14 – 12 foot (45’ - 5660 lb.) (46’ – 5710 lb.)
6 – 24’ aluminum stage Stages - 140 lb. each
Fig. 3-22: 42’, 45’, & 46’ INSPECTION SCAFFOLD 7A5-4, 5, & 6
WITH SUPERSTRUCTURE FOR USE WITH ALUMINUM STAGES

MISCELLANEOUS ITEMS
4.1 Preheat – Basic information
See the explanation in Part 1 paragraph 1.11 for when preheat is required. For a
specific contract, the contract Weld Procedures will define the requirements. The
Superintendent should be issued a copy of Construction Manuals 64 - Preheat & 39 -
Propane Gas Use. Manual 64 describes in detail the various preheat options used by
CB&I and the safe operation of each. Control systems, from temperature indicating
crayons to sophisticated electronics, are covered in the manual. The crayons (Tempil
sticks) are by far the most common method used by CB&I. Manual 39 covers all
aspects of propane use and safety.
When propane preheaters are shut down at the end of the day, the valve at the source
should be closed and the heaters allowed to burn themselves out. This procedure will
prevent gas trapped in the system from leaking into the vessel overnight. Of course all
the valves on the heaters must be closed after they burn out and must be closed when
the main valve at the source is opened the next shift. Persons lighting the heaters
should carry an explosion & oxygen meter and check the atmosphere before lighting
heaters. An effective preliminary test is to bring the system up to pressure before going
to the burners, then shut off the main valve on the tank and see if the pressure will hold
for a few minutes. If it will not, there is a major leak somewhere that needs attention
before proceeding.
It will be cost effective to have a couple of people come in early each day to start up all
the preheaters and get the steel up to temperature before the welders are ready to go to
work.
4.2 PWHT
ASME Section VIII requires PWHT (Stress Relieving) for all carbon steel material over
1.25 inches thick (except that 200° F preheat may substitute for PWHT from 1¼ to 1½
inches in thickness). See Part 1 paragraph 1.15. If a sphere requires PWHT, the work
(including the insulation) will be covered by a contract specific procedure prepared by
Corporate Welding Technology (CWT).
There are several PWHT related items that the construction crew must consider during
erection of the sphere.
1st: The columns will all sit on Jacking Plates. The plates will be on the drawings
and are usually shop fabricated. Grease the top of each Jacking Plate before the
column is set.
2nd: The scaffolds on the outside of the sphere must be full circumference
scaffolds at each level (no vert boards even on large assemblies). The full
scaffolds will be required to install the PWHT insulation.
3rd: The column bracing must not be welded on the lower ends and in fact must
be cut loose because the sphere will grow about 1” in diameter for each ten feet
of sphere diameter during PWHT.

MISCELLANEOUS ITEMS
4th: Any platform, stairway, etc. must have bolted connections loose to allow the
vessel to grow during PWHT.
When ready to begin placing the insulation, follow the Contract PWHT Insulation
Instructions. Follow the PWHT Instructions for the thermocouples and thermocouple
wire installation. A technical person from the District Welding Dept. can be expected to
be on site to perform the actual PWHT.
4.3. Internal and external piping
Internal stilling wells are common on spheres today. These are typically 4” diameter
schedule 10 stainless pipe with collar type joints. The pipe slips through a 6” nozzle on
top and may be supported at the top by a double gasketed 6” flange for 4” pipe or at the
bottom by the guide system. The bottom supported type is preferred.
The ideal method for erecting the stilling well is to ground assemble the pipe into one
lift. Install the guide on the bottom of the sphere directly under the nozzle in the top
head, then lift the pipe with a double choke a little above the center so the lower end will
tip down and can be inserted in the 6” nozzle. The sling must be small enough to go
through the 6” diameter nozzle and long enough so a shackle does not need to pass
through the 6” diameter opening. The pipe will only weigh about 5.9 pounds per foot.
If the crane does not have enough boom to lift the ground assembly high enough to
insert it in the nozzle, the pipe can be assembled vertically in the sphere off a properly
sized tube and clamp scaffold (16’+ for 20’ sections of pipe). Stand up all the pipe
sections inside the scaffold structure. The top section is lifted up through the 6” nozzle
and the lower sections added on as it goes up. Install the flange if required when the
pipe comes out the top.
Another possible method is to build the well from the bottom up using a Spider Buggy
for access. This method will require guylines to hold the pipe until it reaches the 6”
nozzle at the top. An adjacent nozzle through which to rig the Spider Buggy is also
required.
If the sphere requires PWHT, the stainless piping must be installed after PWHT.
Stilling wells with the double flange arrangement should be installed using the
permanent gasket for hydrostatic testing – otherwise the well has to be pulled after test.
Guylines formerly seen on stilling wells for larger spheres should no longer be required
based on the latest vendor requirements.
External piping typically consists of a water deluge system. See paragraph 4.8 for
advice on laying out the supports for these circular piping runs.

MISCELLANEOUS ITEMS
4.4 Spiral stairway erection
The spiral stairway may be a single or double stringer stairway. Single stringers
including the straight portion from grade to the equator are welded assemblies put
together in the shop. Double stringers (including the straight portion) are knocked down
bolted type similar to what CB&I supplies for flat bottom tanks.
For either type of spiral, the spiraled (curved) portion of the stairway should be ground
assembled into one full-length spiral [two if there is an intermediate platform – put the
platform with lower spiral]. The erection procedure for the spiral section is basically the
same as described in Manual 13 for a double stringer stairway on a flat bottom tank.
Connect the spiral to the lower straight section and the upper platform or ramp --- and
let the intermediate supports fall where they will to make the treads level in both
directions.
Avoid having personnel on the stairway, while it is supported by the crane. If this is
required, they must wear a harness and be hooked off to independent lifelines on the
structure.
To ground assemble the double stringer, bolt all the treads in one left or right stringer
section, then bolt on the opposite stringer. Tighten all the bolts after all the treads are in
place. Next bolt all the spiral stringer sections together. Lay the assembly down, treads
up, and bolt on the hand rail system. Care must be taken not to bend the handrail while
initially lifting the assembly. The knee braces may be attached as the assembly is lifted.
If attached previously, take care not to bend or distort the braces or the assembly as it is
lifted. Use the 2 ½ inch rule to lift the assembly so the treads will be close to level in
both directions. See Fig. 4-1.
Knee braces & hand rail +/- 33% L

post not shown for clarity.
21% L +/- 67% L.
Ideal rigging arrangement 42

(varies)
to make the stairway treads
level in both directions. L is
the stringer length
.
58% L
Come close to this arrangement
and the come-along with a little
hand holding will level the treads
in both directions.
21% L
Fig. 4-1 Rigging spiral section of stairway to hang level

MISCELLANEOUS ITEMS
Engineering Assigned does not check the lugs on stairways and platforms for clearance
from weld seams. If the toe of the fillet is less than 1 inch from the edge of a shell butt
weld, handle per contract procedures or per the following procedure from CB&I Red
Book Standard 9301-2.
1. The butt joint shall be welded first, and any RT performed.

2. The surface of the butt weld on the same side as the attachment shall be blend
ground to eliminate notches,
3. MT the blend ground area of the butt weld.
4 Weld the fillet weld and blend grind to eliminate notches.
5. After complete cooldown, both welds must be MT examined.
4.5 Skirt supported spheres
Gas spheres are often skirt supported to save money on the foundations and the
column fabrication. The erection procedures are somewhat different as follows.
A. Check the foundation for level and check the anchor bolt layout. Record all data.
The skirt is erected on level shim stacks (+/- 1/16”) spaced per the contract drawings
based on weight. The anchor bolts are snug – hand tight only -- with the chairs welded if
required. The reinforcement on all skirt openings is installed and welded prior to
erecting the sphere plates.
B. The bottom head square (2 or 3 plates) should be ground assembled if the crane
will handle the weight. If not, set the individual plates in the skirt and temporarily block
under them at the skirt to weld that area overhead.
Do not fit or weld the skirt to the head plates at this time.
Fig. 4-2 Erection of the bottom head on a skirt

MISCELLANEOUS ITEMS
Fig. 4-3 Controlling the position of the head plate on a skirt
C. Erect the four side plates using the key plate layout on the shell drawings (key
nut locations). Key plates and finger bars should be adequate to support the plates. If
necessary, use a pipe or timber support in the center of each plate from the ground up.
Check the level on this course and check the dimension down to the skirt as provided
on the drawings.
Fit and weld the radial seams, then fit and weld the “square” seam. Tack the skirt to the
head plates, but do not weld complete.
Fig. 4-3 Erection of the four side plates on a skirt

MISCELLANEOUS ITEMS
D. Erect the equator plates or ground assemblies (determined by lifting capacity and
assembly area available). Layout the vert locations on the 4 side plates.
Keep the weight as balanced as possible on the skirt as illustrated by Fig. 4-5.
Equator plates or assemblies must be guyed inside and out or supported with pipe
supports similar to those shown in Part 2 paragraph 2.9 for upper hip course plates on
column spheres. The pipe supports will not be plumb because the lower ends must
attach to the side plates below.
Fig. 4-5 Balanced equator course erection sequence – skirt supported sphere
Shown for 54’-9 sphere as single plates and in two plate assemblies
Fit and weld the verts as soon as possible. Weld the girth seam but do not cross an
unwelded vertical joint.
Erect fit and weld the remainder of the sphere as in Part 2 for column supported
spheres.
E. Weld the skirt to the bottom head plates. Tighten the anchor bolts and grout
before test.
A skirt supported sphere will most likely require a full pneumatic test. See paragraph
4.7 and the Contract Test Instructions.

MISCELLANEOUS ITEMS
4.6 Grout of columns or skirt
The columns or skirt must always be grouted before test water is introduced. The type
of grout is dependent on the design of the shear connection between the columns and
the foundation piers and will be defined by the drawings and or instructions for the job.
Flowable, non-shrink, cement grout with strength higher than the concrete in the piers is
often required (both with and without shear bars). Check the drawings, because
ordinary hand packed grout may be satisfactory and is significantly less expensive.
4.7 Hydrostatic, hydropneumatic and full pneumatic testing
See paragraph 1.17 for test planning information. Test pumps, a method for estimating
the time required for filling with water, and the time to pump up to test pressure are all
presented there .
Follow the Contract Test Instructions when rigging for and performing the filling and
testing of the sphere. A level survey for settlement before, during, and after test is
nearly always required.
4.8 Layout and spherical geometry
A common problem on spheres is the layout of points on a horizontal circle. Deluge

system pipe supports are the most common occurrence. The reason it is a problem is
that the arc dimensions between supports can’t be pulled with a tape because the tape
will ride up or down on the shell (up if above the equator, down if below).
The shortest distance between two points on a sphere is a “great circle arc”. A great
circle arc, if continued around the sphere, will make a circle, which has the diameter and
circumference of the sphere.
The arc between two pipe supports that are at the same elevation (on a level line) will
be on what is called a “small circle arc”. The small circle will be a cut through the sphere
like the girth seam between the 4 side plates and the equators. The center will be on the
vertical centerline of the sphere and the radius will be horizontal.
There is no easy way to layout the set of pipe supports. A practical approach is to have
someone calculate the great circle arc length between layout points and the vertical
dimension from the nearest horizontal girth seam. Use the great circle arc to carefully
swing an arc on the sphere from the first layout point to the second. Then pull the
vertical layout dimension from the nearest girth seam and find the intersection. The
vertical dimension can not be swung as an arc like you would in the flat. Keep the tape
vertical and make the dimension fit to the arc. See Fig. 4-6 on the next page.

MISCELLANEOUS ITEMS
Fig. 4-6 Layout of deluge pipe supports or equivalent on small circle
Another method involves the use of a horizontal sweep board cut to the small circle
radius. First determine the distance up or down from the nearest horizontal girth seam;
layout that elevation on the quarter point verts (or more depending on the radius); layout
the first point; then use the sweep board to level over to the next location. The board
should reach from one support location to the next, be premarked with the small circle
arc length, and be rigid enough to project a level line using a carpenter’s level. If the
distance dictates, take two steps to go between supports. The elevation marks on the
quarter points serve to correct the level.

MISCELLANEOUS ITEMS
D. Erect the equator plates or ground assemblies (determined by lifting capacity

and assembly area available). Layout the vert locations on the 4 side plates.
Keep the weight as balanced as possible on the skirt as illustrated by Fig. 4-5.
Equator plates or assemblies must be guyed inside and out or supported with pipe
supports similar to those shown in Part 2 paragraph 2.9 for upper hip course plates on
column spheres. The pipe supports will not be plumb because the lower ends must
attach to the side plates below.
Fig. 4-5 Balanced equator course erection sequence – skirt supported sphere
Shown for 54’-9 sphere as single plates and in two plate assemblies
Fit and weld the verts as soon as possible. Weld the girth seam but do not cross an
unwelded vertical joint.
Erect fit and weld the remainder of the sphere as in Part 2 for column supported
spheres.
E. Weld the skirt to the bottom head plates. Tighten the anchor bolts and grout
before test.
A skirt supported sphere will most likely require a full pneumatic test. See paragraph
4.7 and the Contract Test Instructions.
REWRITTEN AUGUST 1999 / CLB REV 0

MISCELLANEOUS ITEMS
4.6 Grout of columns or skirt
The columns or skirt must always be grouted before test water is introduced. The type
of grout is dependent on the design of the shear connection between the columns and
the foundation piers and will be defined by the drawings and or instructions for the job.
Flowable, non-shrink, cement grout with strength higher than the concrete in the piers is
often required (both with and without shear bars). Check the drawings, because
ordinary hand packed grout may be satisfactory and is significantly less expensive.
4.7 Hydrostatic, hydropneumatic and full pneumatic testing
See paragraph 1.17 for test planning information. Test pumps, a method for estimating
the time required for filling with water, and the time to pump up to test pressure are all
presented there .
Follow the Contract Test Instructions when rigging for and performing the filling and
testing of the sphere. A level survey for settlement before, during, and after test is
nearly always required.
4.8 Layout and spherical geometry
A common problem on spheres is the layout of points on a horizontal circle. Deluge

system pipe supports are the most common occurrence. The reason it is a problem is
that the arc dimensions between supports can’t be pulled with a tape because the tape
will ride up or down on the shell (up if above the equator, down if below).
The shortest distance between two points on a sphere is a “great circle arc”. A great
circle arc, if continued around the sphere, will make a circle, which has the diameter
and circumference of the sphere.
The arc between two pipe supports that are at the same elevation (on a level line) will
be on what is called a “small circle arc”. The small circle will be a cut through the sphere
like the girth seam between the 4 side plates and the equators. The center will be on
the vertical centerline of the sphere and the radius will be horizontal.
There is no easy way to layout the set of pipe supports. A practical approach is to have
someone calculate the great circle arc length between layout points and the vertical
dimension from the nearest horizontal girth seam. Use the great circle arc to carefully
swing an arc on the sphere from the first layout point to the second. Then pull the
vertical layout dimension from the nearest girth seam and find the intersection. The
vertical dimension can not be swung as an arc like you would in the flat. Keep the tape
vertical and make the dimension fit to the arc. See Fig. 4-6 on the next page.

MISCELLANEOUS ITEMS
Fig. 4-6 Layout of deluge pipe supports or equivalent on small circle
Another method involves the use of a horizontal sweep board cut to the small circle
radius. First determine the distance up or down from the nearest horizontal girth seam;
layout that elevation on the quarter point verts (or more depending on the radius);
layout the first point; then use the sweep board to level over to the next location. The
board should reach from one support location to the next, be premarked with the small
circle arc length, and be rigid enough to project a level line using a carpenter’s level. If
the distance dictates, take two steps to go between supports. The elevation marks on
the quarter points serve to correct the level.

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Construction Manual No.

Rewritten August 1999

Revised September 2003

CHICAGO BRIDGE AND IRON CO.

All rights reserved

Part 4 – Minor editorial changes

1. Part 1 is devoted to the planning required of the Construction Supervisor. Eighteen

4. Compression frames are included as an alternate to outside guys when site

Revised Sept 2003 /CD REV 1

19. A section on spiral stairway erection is included in Part 4 paragraph 4.4.

Revised Sept 2003 /CD REV 1

PART 1 PLANNING BY CONSTRUCTION SUPERVISOR

1.0 PLANNING REQUIREMENTS

1.1 SITE SETUP

1.2 CRANE SIZE

1.3 GROUND ASSEMBLIES

1.4 BEVELS – DOWN VS. OVERHEAD

1.5 SCAFFOLDING AND ACCESS

A. SCAFFOLD THE BOTTOM HEAD OVERHEAD

B. ENTRYWAY WITH OVERHEAD PROTECTION

C. TOE BOARDS AROUND BOTTOM OPENING

D. WITH GROUND ASSEMBLIES

I. SHOP INSTALLED COLUMN STRAPS

J. BRACKET STRAPS FOR SPHERES < 60’ DIAMETER

1.6 HITCH LUGS & LANDING ANGLES – CS MUST ORDER

1.8 WELDING PROCESS OPTIONS

1.9 PRODUCTION TEST PLATES

1.10 FIELD INSTALLED NOZZLES AND MANHOLES

1.13 GUYLINES AND COMPRESSION FRAMES

Revised September 2003 / CD REV 1

1.14 PIPE SUPPORTS FOR UPPER AND LOWER COURSES

1.15 POST WELD HEAT TREATMENT

1.16 AUTHORIZED INSPECTION REQUIREMENT

1.17 PRESSURE TESTING

A. PRESSURE & VACUUM RELIEF VENTS

B. TEST WATER (FILL RATES)

C. PUMPING UP TO TEST PRESSURE

1.18 COLUMN FIRE PROOFING

PART 2 SPHERE CONSTRUCTION

2.1 CHECK THE FOUNDATION

2.2 SHIM THE PIERS

2.3 CHECK POST PLATES AND COLUMNS FOR LENGTH

2.4 FIELD FABRICATION OF POST PLATES

2.5 ERECT AND WELD COLUMNS

2.6 ERECT EQUATOR COURSE

2.7 ERECT LOWER HIP COURSE

2.8 ERECT BOTTOM HEAD PLATES (7 PC. HEAD)

2.9 ERECT UPPER HIP COURSE

2.10 ERECTION & WELDING OF COLUMN BRACING

2.11 ERECT TOP HEAD PLATES (7 PC. HEAD)

2.12 GROUND ASSEMBLIES - METHODS, TURNING, & RIGGING

Revised September 2003 / CD REV 1

2.13 FITTING METHODS AND EQUIPMENT

2.14 WELDING PROCEDURES AND SEQUENCE

2.15 CLEAN UP REQUIREMENTS – CARBON STEEL SPHERE – INSIDE AND OUT

PART 3 SCAFFOLDING AND ACCESS

3.0 STANDARD SCAFFOLDING RULES

3.1 BRACKETS AND HANDRAIL POST USED ON SPHERES

3.2 COLUMN BRACKET STRAPS ON COLUMNS 26” ID AND LESS

3.3 BRACKET STRAPS FOR THE INSIDE OF SPHERES < 60 FEET Ø

3.4 THIRD HANDLINES ON COLUMN SCAFFOLDS

3.5 ARRANGING SCAFFOLD FOR WELDER COMFORT

3.6 OVERHEAD PROTECTION AND TOE BOARDS

3.7 ACCESS PATH TO TOP OF SPHERE