Category: Blog

Have You Seen A.R.T.?


 

Manufacturing Bolted Steel Tank videos

As bolted steel and welded steel tanks have evolved over the last 50 years, so has the technology and machinery used to manufacture the tanks. Superior Tank currently uses numerous advanced pieces of equipment including A.R.T. (Automated Robotic Technology). A.R.T. is used in the Rancho Cucamonga manufacturing facility to precisely weld raw materials together to form various tank components.

A.R.T. is a 300lb robot featuring 6 axis of articulation allowing A.R.T. to accurately weld joints in even hard to reach areas. All aspects of the welding process including power, wire, speed and angle of approach are regulated by the computer for extreme consistency and 100% accurate welds. In addition to the accuracy and strength of the welds, the seams are also smoother allowing for better coating coverage and corrosion protection. As errors and weak areas are eliminated, fewer parts are rejected and material waste is minimized.

A.R.T. is used for a variety of tank parts and accessories used with steel water and oil tanks. For example, tank nozzles, flanges, manways and piping are welded together in the factory. When these components are used with bolted tanks, the parts are powder coated then shipped with the tank kit to the installation site. For welded steel tank use, the parts are field coated after being installed onsite.

A.R.T. and other technologically advanced equipment allows Superior Tank to custom fabricate numerous steel tank elements with unmatched precision.

Click here for more information on A.R.T and our manufacturing process!

STCI Installs Bolted Steel Tank for Fire Protection

 

 

In late 2014, Kiewit Construction awarded Superior Tank Company Inc. the contract to manufacture and install a water storage tank as part of a large rail operations center. The facility is part of the $486,000,000 Metro Gold Line Foothill Extension project located in Southern California, and includes 11.5 miles of light rail track as well as an operations and maintenance facility.

The bolted steel tank is part of the Sentinel series of fire protection tanks manufactured by Superior Tank Company Inc. The Sentinel steel tank for the project was engineered to the specific requirements of the project and was designed to store 600,000 gallons of water for fire protection.  The tank meets AWWA D103 standards and applicable local building codes.  In addition, the tank includes special features and complies with NFPA 22 standards to ensure the tank operates properly for fire suppression.  As the tank is considered essential for post-earthquake recovery and is essential to the life, health and safety of the public including post-earthquake fire suppression, the tank was designed to Seismic Use Group III and Risk Category IV standards. This Seismic Use Group is the most stringent and requires seismic design loads be increased 50%.

The exterior powder coating on this Sentinel tank is a custom color to match the other structures on the site and Superior Tank Company Inc. manufactures tanks in a wide variety of standard and custom colors. The high gloss powder coating was applied at the factory using specialized equipment and is expressly formulated for maximum UV resistance.  For exceptional corrosion resistance, encapsulated nuts and bolts were used throughout the tank.

The steel tank was installed by the Superior Tank field team and erection took only twelve days. As other elements of the project were occurring simultaneously, Superior Tank had to coordinate the Sentinel tank installation with the general contractor to eliminate scheduling conflicts.  As only basic assembly work was required on the job site, local traffic and site disruption was minimized.
 
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This is NOT your Father’s Bolted Steel Tank…

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Bolted steel tanks have been used for storage for many years and some older tanks are in use today.  Since the first bolted tanks were put into service decades ago there have been numerous advances in their design and construction.

Modern bolted steel tanks are designed differently than from tanks 30 years ago.  Bolted steel tanks are now designed using 3D modeling software, increasing the speed and accuracy of the process. Select projects are designed using simplified Building Information Model (BIM) software which encompasses the entire project from design to manufacturing then installation. The BIM system can store beneficial ancillary information such as weight and dimension of components and materials used to build the tank.  Design standards such as the AWWA D103 have improved over the last several decades resulting in longer lasting and better performing tanks.  In addition, new tanks are more structurally sound thanks to advances in seismic and wind design methods.

In addition to tank design, the manner in which bolted steel tanks are manufactured has progressed. Originally, steel tanks were manufactured by fabricating raw material by hand or with basic equipment. Small variations in the individual components led to leaks as parts did not fit together properly. Today, bolted steel tanks are precision fabricated using specialized machinery in State of the Art factories. CNC automated machinery ensures extreme accuracy and reduces the fabrication time.  Tank accessories are joined together using robotic welding equipment for 100% perfect joints. In addition, by earning ISO 9001:2008 Certification and following strict procedures, manufacturers can guarantee product consistency and quality.

Innovative options such as factory powder coating have significantly increased the longevity of bolted steel tanks.  The powder coating application process includes spraying a SiZr liquid seal to the prepared steel. The powder coating is applied dry to the steel in an environmentally controlled area to eliminate surface imperfections. The coating is electrostatically applied for 100% coverage without runs, drips and voids. Powder coating formulas are now specially designed for the application; epoxy coating on the interior for continuous emersion and TGIC Polyester on the exterior for outstanding resistance to UV exposure. Once the powder coating is thermoset using mild temperature ovens, it chemically reacts with the steel to form a permanent bond. As all steel components including inaccessible areas such as the underside of the tank bottom are sealed with powder coating the entire tank structure is protected against corrosion.

The hardware used with modern bolted steel tanks has also improved since bolted tanks were first used. To ensure maximum durability of bolted steel tanks, new nut and bolt options were introduced. Encapsulated nuts and bolts are best suited to specific uses and protect against hardware corrosion.  In other applications, hot dipped galvanized nuts and bolts are the best alternative. In addition, the strength of the hardware has increased and bolts used today have a tensile strength of over 120,000 lbs per square inch and now Grade 5 and Grade 8 bolts are used in place of Grade 2. Such advances in tank design, manufacturing processes and materials allow bolted steel tanks up to 3,500,000 gallons to be built.

A final significant improvement which has improved the longevity of bolted steel tank is the introduction of heavy duty synthetic gasket material which is used in place of putty mastic. New gasket material such as ethylene propylene diene monomer (EPDM) is specifically formulated for storage of potable water, wastewater and even brine water.  The thick gaskets are precisely fabricated to fit into the seam between the steel tank panels and provide decades of leak free service. The gaskets remain flexible and therefore they are able to prevent leaks even as the steel expands and contracts due to temperature fluctuations and seismic movement.

When all of these advances are considered, it is easy to see how modern bolted steel tanks are very different than your Father’s Bolted Steel Tank.

“Tank In A Box” is a good neighbor

 

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As most water districts and municipalities have experienced, every new construction project generates some opposition from people living in proximity to the project. In a recent project located in Westlake Village, CA, some residents have been openly very critical of the 5,000,000 gallon concrete water storage tank under construction. One local resident stated he counted 58 concrete trucks entering the construction site every 4 minutes and the construction has nearly caused two separate traffic accidents.

 

Unfortunately, this scenario is not uncommon with concrete tank and welded steel tank construction. These storage tank projects can generate significant negative impact from traffic due to high volumes of deliveries and the large number of workers needed. In addition, considerable noise is created by generators used for welding, concrete pumper trucks and air compressors used for sandblasting and paint application.

 

However, there is a solution which minimizes site impact. Bolted steel storage tanks from Superior Tank are manufactured in a State of the Art factory and then shipped to the job site via semi truck or ocean container hence the term “Tank in a Box”. Bolted steel tanks require only very minimal labor to bolt the tank together and fewer workers are required reducing site traffic. Steel tank panels are manufactured to the exact size needed and no fabrication is performed on site. The durable powder coating with unique SiZr seal is applied at the factory thereby eliminating sandblasting and painting on site.

 

In addition to improving relations with the surrounding community, a bolted steel tank can save a water district or utility considerable time and money. While is it not possible to eliminate all site impact when constructing a new water storage tank, a bolted steel “Tank in a Box” can be a good neighbor.

EPDM, Viton or Buna-N Gaskets – What’s in a name?

Bolted Storage Tank, Storage Tank Gasket, Bolted Tank, Bolted Steel Storage Tank When purchasing a Bolted Steel Tank from Superior Tank, customers have several choices of gaskets. We offer three different premium gasket materials for our steel storage tanks: EPDM, Viton or Buna-N. Selecting the proper gasket material can make a significant difference in the lifespan of the tank.

EPDM (ethylene-propylene-diene-monomer) is a specially designed synthetic rubber for water applications. The general operating temperature for EPDM is -70 to 300 degrees Fahrenheit making it well suited to most water storage applications. In addition to outstanding water resilience, EPDM is very resistant to damage caused by heat, compression, sunlight, acetones, alkalis and ozone. However, it is not recommended for use with acids or hydrocarbons.

Similar to EPDM, Viton is also an elastomer with high yield strength for outstanding durability. Viton is manufactured by DuPont and is specifically formulated for use with most hydrocarbons including corrosive liquids such as crude oil and biodiesel. However, Viton is not recommended for storage of ketones and organic acids. It is also very resistant to compression, heat, acids, alkalis, ozone, sunlight and salt solution. With this tolerance to many harsh liquids and a very wide temperature range of -15 to 400 degrees Fahrenheit, Viton can be used with almost all steel tanks and most storage applications. Viton has years of proven success in the field and provides outstanding durability.

Buna-N is another option when outstanding resistance to oil, hydrocarbon and chemicals is required. Buna-N tank gaskets are comprised of a synthetic rubber copolymer and are very well suited to storage of crude oil and other petrochemicals. When storing ketones, esters and aldehydes in steel tanks, other gasket material is recommended for better longevity. Buna-N gaskets for steel tanks can withstand lower temperatures ranging from -40 to +212 degrees Fahrenheit.

We have found using a formed gasket instead of putty or mastic provides significantly better tank longevity. All gaskets used by Superior Tank are formed to a precise thickness to fit between bolted steel tank panels and remain flexible for many years. The high yield strength of the gaskets ensures they do not tear or leak when the steel expands and contracts with temperature variations. The gasket is a solid material and will not ooze or creep out of place. Our precision manufacturing process places bolt holes in the exact location to prevent bunching up or over stretching of the gasket resulting in leaks. In addition, bolt holes in the gasket are intentionally slightly smaller than the bolts to eliminate gaps and prevent leaks.

The cost of gaskets will vary depending on the material selected and the width required by the tank design. The bolted steel tank experts at Superior Tank can provide guidance regarding the best gasket material for your application and the liquid stored.

Water Storage Tank for Fire Protection Completed

Superior Tank Co., Inc. (STCI) recently completed the manufacturing and installation of a water storage tank for fire protection.Superior Tank Co., Inc. (STCI) recently completed the manufacturing and installation of a water storage tank for fire protection.  The bolted steel water storage tank has a capacity of 320,000 gallons and was installed at the remote testing facility of a large international company.

The steel water tank was manufactured by STCI at their Southern California facility then installed by an STCI Field Crew at the job site. The water tank meets stringent FM Approvals standards for storage of water used in fire protection. Ensuring proper operation of the tank is paramount to saving lives and property in the event of a fire and the FM Approval designation provides the customer confidence that the storage tank will function correctly.

According to Jhon Godoy, Production Manager, “The advanced design of the Bolted Steel Tank allowed us to save the customer considerable time and money.” STCI bolted steel tanks are precision fabricated in the factory and then shipped directly to the job site with all hardware, gasket and fittings. Only basic assembly is required in the field, dramatically reducing site impact. All site hot work such as tank welding and grinding is eliminated, something which is especially important around combustible materials where fire protection equipment is not operational yet. Since steel panels are prefinished with powder coating, there is no need for sandblasting and painting at the job site, reducing air pollution and construction time. Complete tank kits arrive to the location on a single truck and only a small number of workers are needed, thereby reducing site traffic.

The STCI team was able to manufacture and erect the water tank in 1/3 of the time compared to a conventional welded tank design, providing the customer with fire protection much sooner.

Read More “Water Storage Tank for Fire Protection Completed”

What is ISO 9001 For Bolted Steel Tanks?

API, API QMS Registered, API Q1 Registered ISO 9001

Recently Superior Tank Co., Inc. earned the prestigious American Petroleum Institute (API) Q1-ISO 9001:2008 certification for bolted steel oil storage tanks. This certification for manufacturing of oil tanks is a culmination of years of hard work that ensures our oil industry customers will receive the highest quality steel storage tank delivered on time.

API’s audit team reviewed numerous aspects of our tank manufacturing process from sales ordering through bolted steel tank production and tank installation; they determined Superior Tank employs processes and procedures that will guarantee a high quality product. Compliance to strict American Petroleum Institute (API) Q1 and ISO 9001:2008 standards provides customers confidence in our range of bolted steel storage tanks for oil storage.

Superior Tank Co., Inc.’s oil storage tanks are engineered to customers’ needs and range from 100 to 47,000 BBLs. The panelized design of our bolted steel tanks reduces construction time to 1/3 of conventional welded steel oil tanks, saving customers time and money. As the panels quickly bolt together using high strength bolts, no welding is required. The smaller panel size is perfect for tight spaces within an infrastructure, and large staging areas are not needed. The heavy duty API compliant gasket seals panels together and provides decades of leak free service. Custom made tank fittings and piping are installed for each application to ensure a perfect fit.

Premium power coating specifically tailored for corrosive environments is used on all oil storage tanks. As the powder coating is electrostatically applied at the factory, the “coverage is perfect 100% of the time” states Eric Marquez, Plant Manager. For additional durability, the edges of each tank panel are double coated.

Complete tank kits are shipped directly to the job site via truck or standard shipping container. Our tank field teams based in California and Texas provide full installation services throughout North America.

In addition to API Q1-ISO 9001:2008 certification, Superior Tank recently earned
FM Approvals Certification on our water storage tanks for fire protection.

Read More “What is ISO 9001 For Bolted Steel Tanks?”

Bolted Steel Tanks Immune to Shortage of Welders

Bolted Steel TankSince 1988, the United States has experienced a significant decline in the number of welders. According to the American Welding Society there is a potential shortage of 200,000 skilled welders resulting in project delays and increased costs.

To counteract this shortage and thereby save customers time and money, Superior Tank Co., Inc. (STCI) offers a full range of large capacity bolted steel storage tanks. Unlike other storage tank designs which are welded and require a significant amount of welding, bolted steel tanks eliminate the need for costly onsite welding. The limited amount of steel welding required for STCI tank fittings is performed by a robotic welding arm ensuring 100% accuracy.  Steel panels are crafted using precision machinery inside the STCI modern production facility then shipped to the job site. The advanced bolt together design of STCI steel tanks allow for quick and simple assembly on site.

By performing steel fabrication in the factory, the amount of noise and air pollution on site is dramatically reduced. The steel tank panels are delivered to the site via one or two trucks lessening local traffic and negative impact.  In addition to saving welding costs, STCI bolted steel storage tanks reduce onsite painting costs as the steel panels are prefinished with durable powder coating.

With the high cost and shortage of welders forecast to continue for the foreseeable future, bolted steel storage tanks are certain to continue to increase in popularity.

Is a ‘Tank in a Box’ Right For Your Next Project?

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Bolted steel water storage tanks are nothing new and have been used for decades with great levels of success. These tanks are sometimes referred to as a “Tank in a Box” due to the modular design of bolted steel tanks, which allows them to be packed and easily shipped anywhere in the world. Commonly, tanks are shipped via truck or standard shipping container. Tank kits come complete with hardware and fittings, and are ready to erect upon arrival. When properly designed, manufactured and installed, a “Tank in a Box” meets a wide variety of applications.

The unique modular “Tank in a Box” design is based on the use of individual heavy gauge steel plates, which are used to form the tanks. These plates are prefabricated in dedicated facilities using a variety of specialized equipment such as press breaks, robotic welding arms, drill presses and coating machinery. The final finish is applied to all tank components before they are packed for shipping. The components are precision-manufactured for longevity and a well-crafted bolted steel tank can provide over 60 years of service.

Once on site the tanks quickly bolt together with minimum site work. The erection time of a bolted tank can be as little as 1/3 of the time required to construct a similar size welded tank. In addition, the plates arrive to the job site complete with final finish already applied, eliminating the need to sandblast and paint on site. As the tanks only need to be assembled, they can be erected in various weather conditions and are resistant to adverse weather delays.

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Glass Coated Tanks – Worth the Money?

Glass TanksOf all the questions we are asked while attending trade shows all over the world, the following questions are the two most common: first; “What are the advantages of factory powder coated tanks over glass-coated tanks?” and  “are they really cheaper than glass-coated tanks?”.

One of the most important points to consider when deciding between a glass-coated tank and a powder coated tank is the tank’s life cycle cost. Two of the most common misconceptions are that glass-coated tanks are cheaper because they never need to be recoated and that a glass-coated tank will last forever. Well…… false in the first count, therefore, false in the second count; glass-coated tanks are very rigid and have little flexibility. They are more often than not subject to coating failure at the bolt heads and edges, making them vulnerable to corrosion attacks. There have been many incidents of spalling, where glass has flaked into stored liquids within the first 5 -10 years of the tank’s life. That’s pretty disturbing, especially if you are the end user, relying on the quality of the water stored inside the tanks.

One more item to consider in your “worthiness checklist” is that glass-coated tanks are not entirely coated; parts of the structure (wind girders, nozzles, rafters, etc.) are made of galvanized steel, the tank’s top is aluminum and the bottom is concrete. This means that cathodic protection will be required and the maintenance of such a system is a continuous and expensive burden, to say the least.

Wear and tear is an inevitable issue for all tanks. Considering that a glass coated tank cannot be recoated in the field, the downtime for maintenance is a huge cost issue; selecting the right coating for your needs should be a top priority.

At the end of its life cycle, a glass-coated tank must be totally dismantled and sometimes fully replaced. This means field repair is not an option and the extended service life is nonexistent. Now, all of a sudden the total life cycle cost of a glass-coated tank becomes astronomical. It doesn’t seem to be worth the money after all, does it?

We pioneered the use of powder coating in the industry 24 year ago for two indisputable reasons: quality and durability. These reasons have been the driving force for excellence behind our products, making powder coated tanks reliable and trouble free. Ask around, you won’t regret it.

If you stop and think about what makes the purchase of a bolted steel storage tank successful, you will realize that choosing the right coating is fundamental in achieving the savings and trouble-free storage you desire. Factory powder coated tanks seem to be not only the wisest choice, but the only choice.

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