HYDRAULIC JACK SET-UP

OP E RATI O N MANUAL

CONTROLLED DOCUMENT
NOTICE: Special approval is required before this document may be released.
This document is considered confidential and proprietary information, and may not be reproduced as a whole
or in part without the expressed written permission of the Tank Connection Quality or Executive management.
(See TC document # QF-038 for more information.)

© 2015 Tank Connection Affiliate Group TC Doc: Q-077 • Rev: 1 • Date: 12/8/2015
 HYDRAULIC
HYDRAULICJACK
JACK
SET-UP
SET-UP
&&OPERATION
OPERATIONMANUAL
MANUAL

Disclaimer

This manual is not designed to train an inexperienced crew

on hydraulic jack operations. It is designed to assist in
understanding how the jack components are set up and
describe the operation of the jacks.

Under no circumstances should an inexperienced crew

attempt to operate jacks without proper training or a
trained supervisor present.
 HYDRAULIC
HYDRAULICJACK
JACK
SET-UP
SET-UP
&&OPERATION
OPERATIONMANUAL
MANUAL

TABLE OF CONTENTS
Preface....................................................................................................................................1

Number of Jacks Required....................................................................................................1

Light Lift Assemblies............................................................................................................................................1
Standard Lift Assemblies....................................................................................................................................1
Heavy Lift Assemblies..........................................................................................................................................1

Hydraulic Pump And Manifold Systems..............................................................................2

Jack Assembly........................................................................................................................2

Jack Installation................................................................................................................. 3-4

Positioning Jacks...................................................................................................................................................3
Jack Placement - Concrete Floor......................................................................................................................4
Jack Placement - Bolted Steel Floor................................................................................................................4

Attaching Jacks to Hydraulic Manifold................................................................................5

Lifting Plate Attachment.......................................................................................................6

Jacking the Tank/Silo...................................................................................................... 7-10

Lowering And Reconnecting Jacks................................................................................... 10

 HYDRAULIC JACK SET-UP & OPERATION MANUAL 1

PREFACE
It is imperative the jacking system be set up properly to assure safe and successful lifting of flat panel bolted tanks. Although the
system has been designed to withstand extreme weights, improper assembly or operation can cause catastrophic failure.

NUMBER OF JACKS REQUIRED

Tank/Silo total weight determines how many jacks are required to lift efficiently and safely. If the total tank weight divided by total
number of vertical seams (number of panels in one ring) is:
• 4,500 pounds or less, see “Light Lift Assemblies” (9,000 pounds or less per jack)
• More than 4,500 pounds, and 10,000 pounds or less, see “Standard Lifting Assemblies”
• More than 10,000 pounds, see “Heavy Lift Assemblies”

Light Lift Assemblies

Placing jacks at every other seam of the tank can be utilized when jacking weights don’t exceed 9,000 pounds per jack at
maximum capacity. A minimum of 3 jacks must be utilized when operating the jacks in this fashion.

Standard Lift Assemblies

A jack is placed at every vertical seam on the tank/silo. Maximum capacity at each jack should not exceed 10,000 pounds without
proper authorization from Tank Connection Engineering Services.

Heavy Lift Assemblies

Jacks are placed at every vertical seam of the tank/silo and intermediate jacks are placed equally between those jacks on the
vertical seams. When using jacks in this fashion, the number of intermediate jacks can be any factor of the number of vertical
seams (number of jacks evenly divisible by number of intermediate jacks), minimum of three additional jacks, up to an equal
number of intermediate jacks corresponding to the number of jacks used on the vertical seams.

EXAMPLE: 12 vertical seams = 12 jacks. Intermediate jack options would be:

• Add 3 intermediate jacks between vertical seams every 4th panel
• Add 4 intermediate jacks between vertical seams every 3rd panel
• Add 6 intermediate jacks between every other vertical seam
• Add 9 intermediate jacks skipping every 3rd panel
• Add 12 intermediate jacks between every vertical seam.
When using this scenario, jacking weights should not exceed 11,500 pounds per jack.

NOTE: To place intermediate jacks, the crew will need to field drill the mounting holes for the lifting plates.
NOTE: Any lift that will exceed #11,500 per jack must be approved by Tank Connection engineering.
 2 HYDRAULIC JACK SET-UP & OPERATION MANUAL

HYDRAULIC PUMP AND MANIFOLD SYSTEMS

There are two different configurations of systems available. One system utilizes a single cart unit with a hydraulic motor driven
pump, hydraulic fluid reservoir, and distribution manifolds. This system is designed in a 20 jack and smaller combination.

The larger system utilizes two carts, one cart has the hydraulic pump and reservoir and the second cart holds the distribution
manifolds. This system is designed in a 40 jack and larger systems. The carts are connected together with larger ½” diameter
hydraulic lines with quick couplers.

Each system can be used up to its total number of ports or any combination of jacks less than the total number of ports provided
and operate at a maximum total working pressure of 1500psi.
NOTE: Do not modify or adjust the units to exceed the maximum operating pressure of 1500psi as damage may occur to
the jacking system.

Verify the engine has oil and the hydraulic reservoir is full. Units shipped internationally are sent without oil or hydraulic fluid due
to shipping requirements

JACK ASSEMBLY
Jacks may arrive at the site with the bottom support frames removed to minimize shipping size of the jack assemblies. With
the jacks laying down in a horizontal position, check the lifting tubes to verify that they slide easily in and out of the jack and
the second stage lifting tube. Verify they have grease applied to all four sides of each tube. Inspect all welds on the assembly
and assure there are no damages to the hydraulic lines, valves or couplings to the jack cylinder which may have occurred in the
shipping process.

The base consist of a horizontal angle “heel” plate and two flat diagonal wings. To assemble, lift the jack into the vertical position
or support the base of the jack with a 4” X 4” block to allow the angle to be installed. Place the base angle with the leg under the
lifting tube of the jack, aligning the bolt holes on opposite sides of the jack tube. Install bolts pointing toward the inside of the
jack, with a flat washer under the bolt head and a lock or flat washer under the nut. Screw the nuts on finger tight to allow for
adjustment once the jack is set in position. Install the diagonal braces on either side of the jack tube attaching to the mounting
plate welded to the tube and attach the lower ends to the angle base previously installed. Install the mounting bolts in the same
manner as the base and install nuts finger tight. Stand the jack vertical and complete the assembly of all jacks required for the
tank assembly.
 HYDRAULIC JACK SET-UP & OPERATION MANUAL 3

JACK INSTALLATION
NOTE: All jacks must be placed at the same height in elevation +/- 1/8”.
Shim or block as required to bring them within tolerance.
On concrete floors, it is recommended that elevation measurements are
taken at each jack placement location. Set the highest jack first and shim
the remaining jack bases to bring them within the 1/8” +or- tolerance as
required.

On tanks with steel floors, the jack bases should be placed on 1-1/2” thick
wood block bases. This will prevent damages to the floor coatings and also
allow the jacks to clear the floor bolted seams. Should a floor radial seam
run under the jack base, then wood blocking should be placed on both
sides of the seam, as close to the bolt line as possible to provide adequate
support. It is not necessary to have solid blocking under the jack bases but it
is recommended that blocking be at least 4” nominal width. Blocking should
be placed under the base angle and directly below the vertical tube which
houses the jacking cylinder and vertical stage sections that lift and support
the tank. Additional blocking can be added on each end of the base angle
for support. On the jack inner base channel, welded to the jack, blocking
should be placed where it is directly below the welded gussets that come
down to the channel from the jack frame.

Positioning Jacks
Draw a line from the center line of the vertical seam down to
the base angle of the tank/silo.
NOTE: Refer to installation drawings to determine the proper
vertical seam for jack attachment when tanks/silos
have multiple vertical bolt seams at the sidewall laps.
On the back of the jack, the side that will face the tank wall,
mark a line on the center of the lifting tube jack frame down
onto the installed base angle. Place the jack on the support
blocking against the tank wall aligning these marks made on
the tank base and the jack. On the jack base angle there is a
channel block welded to the angle, which sets the jack the
proper dimension off the silo wall, approximately 2-1/2”-3”.
The jack must be set as close as possible to the sidewall of the
tank to minimize deflection of the jack lifting plates.

NOTE: On dry silos the base angle will interfere with setting the spacing block directly against the silo interior wall. Due to this,
when lifting over 8000# per jack, the jacks will either need to be blocked up to set above the base angle, or they must be
tilted out of plumb toward the silo wall so as the jack is extended it will cause the lifting tube to move toward the wall.
The jack will only need to be angled a slight amount, generally 1/8”-1/4” in 4’ of height out of plumb toward the silo wall.
 4 HYDRAULIC JACK SET-UP & OPERATION MANUAL
Jack Placement – Concrete Floor
On concrete floors the jacks can be anchored with three (3) ½”
diameter by 3” minimum embedment drill in concrete wedge
anchors; two (2) in the jack base angle, one on each end; and
one in the inner channel brace. Holes are provided at these
locations for anchor placement. Drill in the anchors at each
end of the base angle for the jack. Install these anchors and
tighten sufficiently. Plumb the jack vertically off the base angle
and tighten the attachment bolts in the jack base angle to the
jack frame, and the bolts in the diagonal braces on either side
of the jack frame, (4) four bolts total for these. Then plumb the
jack vertically toward the tank wall and shim the base channel,
if needed, at the concrete anchor bolt location to hold it
vertical.
NOTE: As indicated the jacks may be plumbed at a slight outward angle if needed to compensate for the silo base angle
interference. Do not allow the jacks to angle away, or toward the tank interior! They must be set vertical or lifting
slightly outward. The final anchor in the channel can now be installed and tightened.

Jack Placement – Bolted Steel Floor

Place the jacks on wood blocking as noted previously. Center
the jack on the vertical tank seam and push the jack spacer
block within ¼” of the tank interior wall.
NOTE: if the tank does not have a starter ring and the
jacks are being aligned to the tank base angle, the
jack set back from the wall should be ¼” plus the
thickness of the bottom sidewall panels. Example ¼”
setback + ¼” bottom sidewall thickness = ½” setback.
Once the jack is set in position, install a one-hole angle clip in
line with the outer anchoring holes in the jack base angle on
each end. Then utilizing the slotted tie down straps, bolt one
end to the angle clip and the other end to the mounting hole
in the jack base angle. Tighten these bolts and this will retain
the jack at the proper position against the wall.
NOTE: The one hole angle clips and retaining straps can be attached to the base angle seam slightly outward of the base
angle ends to facilitate ease of installation, but they must be kept as close as possible to prevent twisting or movement
in the jack base.
Once the jack base angle is retained on each end, plumb the jack vertically side to side and tighten the attachment bolts at the
jack base angle and jack lifting frame and each diagonal support on each side of the jack. The inner channel of the jack base must
be shimmed to plumb the jack level to the wall.
NOTE: The inner channel end does not have to be anchored when the tank being constructed is less than a 2/1 diameter to
height ratio. When the tank height exceeds this ratio, field fabricated angles must be used to attach across floor seams
and the inner base channel must be retained to prevent uplift.
 HYDRAULIC JACK SET-UP & OPERATION MANUAL 5

ATTACHING JACKS TO HYDRAULIC MANIFOLD

Each jack is attached to the manifold with two (2) ¼” diameter
hydraulic lines and quick couplers. Some of the jacks have the
lines already attached to the hydraulic cylinder in the jack and
are just coiled up in the jack bases. Some lines are shipped
loose and quick couplers are provided on the line ends to
attach them to the jack cylinders. Whether hydraulic lines are
shipped attached or loose, all lines will have quick couplers on
the ends which attach to the hydraulic manifold.

Place the hydraulic pump with manifolds or the manifold cart

in the center of the tank, use padding or blocking on steel
floors to prevent coating damage. Uncoil the lines from the jack out to the manifolds, excess line length should be coiled up near
the manifold location to prevent trip hazards at the tank or silo wall where the tank/silo panels will be installed. The manifolds
on the units have a series of quick couplers on each side, one male and adjacent to it one female. The jack hydraulic lines are
connected to each adjacent, male/female coupler.
NOTE: Verify the end is clean and free from contaminants. Damage can occur to the hydraulic seals and pump if dirt or other
contaminants enter the system, prior to attaching any hydraulic line. Spray cleaners, such as brake parts cleaner, can be
used for cleaning.
Place a small amount of oil on the male fitting and connect the lines from the jacks to the manifolds. It is recommended that if
all manifold ports are not needed that you start the attachments at the closest ports to the pump and work outward from there.
Do NOT run lines over the manifold or pump to make connections on the opposite side. Lines should be connected to either
side of the manifold that is nearest them. Should a set of lines need to be attached to the opposite side of the manifold, the lines
must be run around the base of the unit on the floor and then
attached.

NOTE: Jacks are only provided with 30’-35’ hydraulic hoses,

large diameter tanks or silos exceeding 70’ in
diameter will require special “extended length” hoses
or additional hose extensions for the system to be
used.
 6 HYDRAULIC JACK SET-UP & OPERATION MANUAL

LIFTING PLATE ATTACHMENT

Lifting plates are fabricated with multiple holes vertically to correspond with the
tank/silo vertical seam punching. It is recommended to attach the lifting plates low
in the vertical seam on the ring to be lifted to make it easier to access when they are
needing to be removed after the lift is made.
With the lifting plate installed on the jack, verify the lowest hole in the vertical seam
that will align with the lowest hole in the lifting plate.
NOTE: There must be, at a minimum, one vertical seam bolt below the lowest
attachment point of the lifting plate.
It may be necessary to not use the lowest holes in the lifting plate to allow the
minimum one bolt in the vertical seam.

The lifting plate is attached using longer fin-neck full shank tank bolts. The bolts
must be long enough to prevent the threaded portion of the bolt from being in
the lifting plane. To compensate for the excess bolt length,
additional washers will be used under the nut to allow the
bolts to be tightened “snug tight”.

A minimum of two lifting bolts must be used in each lifting

plate for any amount of weight to be lifted up to 3000
pounds, 3 lifting bolts must be used in 3001 to 6000 pounds,
4 lifting bolts from 6001pounds to 8000pounds, 5 lifting bolts
from 8001 to 10,000 pounds, and 6 bolts for lifts above 10,001
pounds to 11,500 pounds.

Lifting bolts should be staggered in the seam, two bolts

together in the lower seam, then a minimum of one tank bolt
retaining the vertical seam, then another two lifting bolts, and
then another seam bolt, continuing upward for the quantity
of lifting bolts required.

NOTE: Some crews will separate the lifting bolts further along the plate which is acceptable. No more than two lifting bolts
should be placed adjacent to each other in the seam.
The number of intermediate jack lifting bolts, where the lifting plate mounts flush to the tank wall, can be reduced by one from
the adjacent vertical seam to minimize the number of field drilled holes that must be located. A minimum of two bolts must be
utilized and the lifting bolts must be snugged sufficiently to fully seat the lifting plate against the tank wall where the lifting bolts
are installed.

Hang each lifting plate on the jacks and determine the closest connection point in the seam.
NOTE: Lifting plates may have to be raised to align with a hole.
Lift the plate up as required and install a lifting bolt, as described above, through the plate and seam. Have a worker on the
exterior apply washers and a nut to the bolt. Install the subsequent lifting bolts through the seam as required and have the
worker install washers and nuts. On tanks with plastic encapsulated hardware a ¼” thick wood shim must be placed between
the lifting plate and tank wall adjacent to each lifting bolt. This will prevent the plate from damaging the bolt heads of the seam
bolts installed behind the lifting plates. Shimming is not required on plates that do not have plastic capped bolts between them
and the sidewall. Once all lifting bolts have been installed, have the worker on the outside tighten each lifting bolt “snug-tight”.
Continue around the tank and attach all lifting plates as described. Once complete, verify all lifting plates are set at the same
elevation on each jack, this will assure that the tank is set level at the mid-point stage pin.
 HYDRAULIC JACK SET-UP & OPERATION MANUAL 7

JACKING THE TANK/SILO

Verify that all jacks have been connected to the hydraulic manifold and the connections are secure by grasping each line and
giving it a slight pull. This will make sure they are coupled completely. Also verify the main lines from pump to manifold carts are
connected if using the larger separate system.

On each jack there are two (2) valves, the upper valve is a gate valve and should be open, handle in line with valve, during
operation. This valve is used to stop the lifting operation of the jack as needed to level the tank during the jacking process.

The lower valve may be a gate or needle valve. This valve is used in conjunction with a one-way check valve located in the lower
“lifting” hydraulic line. To operate the t-handle needle valve, turn it clockwise to close or counter-clockwise to open. Do not
apply excessive force to the handle when fully opened or closed, as it only needs to be turned in/out to where it stops. Forcing it
closed/open will cause damage to the valve. The valve is closed during the lifting operation and opened when the jack cylinder is
lowered.
 8 HYDRAULIC JACK SET-UP & OPERATION MANUAL
At the top of the jack there is a restraint chain and tube that is applied over the one side of the second stage lifting bar. The chain
keeps the second stage seated while pushing the first stage out. Install the restraint during the first stage lifting process.
Each jack will require one (1) second stage tube pin and one (1) second stage lifting block. These are shipped loose and should be
placed by each jack.

A minimum of two workers will need to have a tape measure to check the level tolerance on the tank during the lifting process.
To lift the tank, start the motor on the hydraulic pump and allow to idle a few minutes to warm up. Verify the top valve at the jack
is open and the bottom valve is closed. Verify the second stage tube restraint is installed and have one stage lifting pin and second
stage lifting block for each jack available. Increase the motor speed on the hydraulic pump motor to full open high run position.
Slowly move the control handle toward the “UP” position to start the hydraulic flow to the jacks. Verify there is no visible hydraulic
leaks and each jack cylinder has started to extend. Slowly move the handle more toward the up position and verify the tank/silo is
starting to lift out of the sheet stands.

After verifying all items listed are operating properly, the control handle can be moved more toward the up position to increase
the hydraulic flow to the jacks.
NOTE: When using less than the full capacity of jacks that can be operated on the unit, it may be necessary to not operate the
control valve in the full up position.
Although it does not harm the system if operated fully, the drive motor may not operate efficiently and may even loose power
and die when trying to operate it this way. This is caused by back pressure on the system from the system not having all of the
possible jacks connected.

During the lifting operation it is not uncommon for the tank/silo to lift unevenly. Therefore crew members should check the
elevations on the lifted assembly around the tank perimeter during the lifting operation. The tolerance during the lifting
operation is limited to 1” of maximum variance. Should workers find that the level is at the maximum tolerance, workers should
close the upper valves on the “high side” jacks. This will allow the jacks on the side which is lower to push the tank up to the level
point. Continue to raise the low sides past the high side points approximately ½”. Once that level is achieved, the valves that were
closed on the jacks can be opened and the full lifting of the assembly can resume.

Continue the lifting operation for the first stage of the jacks. This will be approximately 35” of height, which is verified when all
of the pin holes are exposed on all of the jack first stage tubes. Shut off the hydraulic pump when the first stage if fully lifted and
the pin holes in all accessible. Place a jack pin through the hole in the first stage tube, verifying that the shoulder of the pin head
is outside of the pin rest. Once all first stage pins are in place, workers will need to open the lower valves of all jacks. Restart the
hydraulic pump, and slowly move the control valve to the down/lower position allowing the first stage tubes to rest on the pins.
Once all tubes have rested, increase the handle position to the down/lower direction and this will retract all of the jack hydraulic
cylinders.
NOTE: It is not uncommon for some of the cylinders to retract faster than others. If there is a cylinder that is not retracting at
all, first verify that both valves on the jack are in the open position.
If they are open and the jack still does not retract, close and re-open the bottom valve, and also verify that both hydraulic lines are
connected properly to the manifold of the hydraulic unit. In most instances, when the cylinders do not retract, it is generally due
to the lower valve not being opened fully.
 HYDRAULIC JACK SET-UP & OPERATION MANUAL 9

Continue retracting the cylinders on the jacks until all of them are at the fully
retracted position. Shut off the hydraulic pump once complete. Workers will then
go to each jack, close the bottom valve, remove the second stage restraint chain
and tube, and install the second stage lifting block.
NOTE: The second stage lifting block must be fully seated on the lifting arms of
the second stage tube to prevent dislodgment when the second stage is
being lifted.

Prior to starting the hydraulic unit, verify that all lower jack valves are closed, all
upper jack valves are open, and the second stage lifting block is installed and
seated properly. Once complete, restart the hydraulic pump and slowly move the
control lever to the lift/up position, verify that each cylinder is extending and the
tank/silo is beginning to rise again.

NOTE: When raising the second stage it is important to continually monitor the
lifting height of the assembly to maintain the levelness tolerance as
described in the first stage lifting.
The assembly should be raised to a level point which allows between 1/8” and
¼” additional height when the next ring of sidewall panels are being installed.
Example: on a full height sidewall panel the overall height from centerline of the
horizontal seam bolt holes in the lifted assembly and the top of the sheet stand
should be 59-1/8” to 59-1/4”. The tolerance is +/- ¼” but the assembly cannot be
any lower than 59” which is the exact dimension of the panel edge to the hole
centerline.

Continue the lifting operation for the second stage assembly, monitoring the
height of the assembly. When the assembly is within 2” of the final height stop the
jacking operation. Have the workers check the height at each jack and determine
where/if there is a high point. After the high side is determined, start the jacking
process again and stop the jacking process when the high side area achieves
the desired height. Shut off the upper valve on the jacks that have achieved
the proper height, this will prevent the jack from extending further. Then go
to the next highest area, start the jacking operation and stop when it achieves
the proper height, again shut off the upper valve on the jacks at this location.
Continue this process until all jacks have achieved the proper height.

Verify all upper valves on the jacks have been closed and shut off the hydraulic
pump motor.

NOTE: Do NOT unhook the hydraulic lines from the pump/manifold unit. All of
the hydraulic lines must stay connected and all of the valves on every
jack must be in the off/closed position.
 10 HYDRAULIC JACK SET-UP & OPERATION MANUAL
The next ring of panels around the tank/silo is now ready to be installed as
described in the corresponding installation manual. It is permitted to leave
out one panel in the ring to allow access for workers in/out of the tank/silo. All
installed panels must be bolted up fully, prior to the next stage of the jacking
operation.

LOWERING AND RECONNECTING JACKS

To lower the jacks, open the top and bottom valve on each jack, and without the pump running just move the control handle to
the down/retract position. This will allow the tank/silo to rest in the sheet stands and relieve the pressure on the jack face plate to
wall attachment. Workers will then go around and removes the nut and washers from the jack lifting plate to sidewall attachment
bolts.
Note: There may still be a slight amount of pressure on the bolts so just remove the nuts and washers at this time, the bolts will
be removed in the next step.

Once all of the nuts and washers are removed from the lifting bolts, start the hydraulic unit and move the lever to the down/
retract position to allow each cylinder to retract between 1/2” to 1”. Release the hydraulic control handle, leave the power unit
idling and detach the lifting plates from the sidewall by removing the lifting bolts. Once complete, speed the hydraulic drive
motor up to maximum and move the handle to the down/retract position retracting all jacks cylinders completely. Shut off the
hydraulic power unit, and have workers go to each jack and remove the second stage lifting block and close the lower valve at
each jack.

It is not necessary to operate the hydraulic cylinders on the jacks to lower the first stage sections. To lower, have a worker place the
end of a 4’ long 2x4 wood slat on the inner edge of the stem head where the hydraulic cylinder contacts. This worker will push up
slightly on the stage and another worker can then remove the stage pin. The worker with the 2x4 can allow the stage to slide back
down controlling the decent with the 2x4 wood slat.

NOTE: Workers must keep their hands clear of the jack at all times during this process as the lifting tube can drop and
cause physical harm if hands or persons are touching the jack. Do not remove the pin and allow the tube to retract
without controlling the descent, this will cause damage to the jacking unit.

Once all 1st stage jacking tubes are down at the starting position, workers can then fill in the bolts used for the jacking plate in the
upper ring of panels and reconnect the face plates to the next section to be lifted as described previously in the manual.