Constructing Precision-Engineered Storage Tanks: A Technical Overview

The fabrication of storage tanks is a process approached with meticulous attention to detail by our engineering teams. This article aims to provide a comprehensive overview of the procedural steps undertaken to ensure the structural integrity and operational success of storage tanks designed for a variety of applications.

Given the diverse requirements of storage tank construction, based on tank dimensions and intended use, the methodology may be adapted; however, the core stages of installation are universally applicable.

Initial Site Preparation

Selecting an optimal location forms the foundational step in tank construction. Critical considerations include:

  • Soil stability analysis
  • Strategic accessibility evaluation
  • Proximity analysis regarding utilities

Subsequent to the determination of an appropriate site, the preparation phase involves vegetation clearance, ground leveling, and conditioning to facilitate the onset of construction activities.

Foundation Engineering

Comparable to the principle that a robust house requires a solid foundation, the construction of a storage tank begins with establishing a strong base. The foundation options predominantly include a reinforced concrete pad or a compacted gravel base, tailored to the specific load requirements and structural specifications of the tank.

Shell Assembly

The assembly phase marks the commencement of the tank’s physical construction. Utilizing high-grade steel plates, the tank’s shell is constructed in a sequential layering process, with each ring securely fastened to its predecessor. The adoption of bolted connections over welding techniques significantly enhances assembly efficiency, reducing installation time compared to conventional methods.

Roof Installation

Following the shell assembly, the construction of the roof involves the installation of structural supports, beams, and decking, culminating in the placement of the roof. Specialized roofing structures, such as geodesic domes, are integrated at this juncture as per design requirements.

Integration of Safety and Accessibility Features

To facilitate maintenance and operational integrity, the addition of ladders, platforms, guardrails, and anti-slip surfaces is essential. These features are designed to ensure safe and convenient access for maintenance personnel and staff.

Fitting and Connection Configuration

The operational functionality of storage tanks often necessitates the integration with external systems. Accordingly, our team installs essential fittings including valves, vents, and connections to accommodate supply lines, pumps, and ancillary equipment, ensuring compatibility with the tank’s intended application.

Comprehensive Testing and Certification

Ensuring compliance with industry standards (e.g., AWWA, Eurocode) is paramount. Our team conducts thorough leak detection, and visual inspections to certify the tank’s integrity and operational readiness, adhering to rigorous quality assurance protocols.

Project Finalization

Upon successful completion of testing and inspection phases, a final review is conducted to ensure all components are securely integrated and fully operational, marking the readiness of the tank for service.

Collaborative Engagement and Expertise

At FORGE, our engineering team brings extensive experience in design and construction to each project, committed to delivering tailored solutions that meet specific application needs and site conditions. We pride ourselves on quality installations and enduring customer relationships.

For storage tank solutions and expert consultation, we invite you to dialogue with our team. Explore how our engineering expertise can serve your storage requirements by requesting a quote or engaging with our professionals today.

 

Optimizing Storage with FORGE: Engineering Excellence for Your Storage Tank Needs

In the realm of storage tank solutions, selecting the right partner is pivotal for the successful execution and longevity of your project. FORGE stands at the forefront of this industry, offering unparalleled expertise, precision engineering, and a commitment to solving complex challenges. This blog outlines the tangible benefits of collaborating with FORGE, underscoring our dedication to delivering superior storage tank solutions that cater to the rigorous demands of various sectors.

Tailored Engineering Expertise

At FORGE, our foundation is built on a deep-seated understanding of the engineering challenges and requirements associated with storage tanks. Our team comprises in-house engineers who bring a wealth of knowledge and experience to each project. Unlike other providers, our direct access to engineering expertise ensures that every tank is designed and constructed to meet the highest standards of quality and efficiency, tailored to the specific needs of your operation.

Proven Problem-Solving Approach

The capacity to navigate and resolve complex engineering challenges distinguishes FORGE in the storage tank industry. Through a series of case studies, we demonstrate our problem-solving prowess:

  • Cement Storage Project: Faced with a critical timeline, FORGE efficiently dismantled and relocated storage tanks for a client, significantly reducing downtime and exceeding project timelines.

  • Digesters: When Digester customer encountered delays due to inexperienced contractors, FORGE expedited the completion of 16 large digesters by deploying multiple experienced crews, establishing a lasting partnership based on reliability and performance.

  • Export Oil Exploration: Tasked with installing storage tanks in a remote location under tight deadlines, FORGE showcased exceptional project management and logistical capabilities, delivering the project flawlessly against formidable odds.

Dedicated Project Management and Direct Execution

Our commitment to providing a seamless and efficient experience is evident in our approach to project management. Each project is overseen by a dedicated manager, ensuring a single point of accountability from inception to completion. Unlike competitors who may rely on subcontractors, FORGE utilizes its own skilled crews for every aspect of the project. This direct control over the workforce enables us to maintain the highest quality standards, accelerate installation timelines, and ensure the integrity of the final product.

Speed Without Compromise

In the fast-paced world of industrial and energy sectors, time is often of the essence. FORGE’s innovative methods and skilled workforce allow for the installation of storage tanks up to three times faster than industry averages, without compromising on quality or safety. This efficiency can be a critical factor in reducing project timelines and operational downtime, providing our clients with a competitive edge.

Forge a Partnership with FORGE

Our invitation to potential clients is clear: bring us your challenges, and in return, we will deliver solutions that not only meet but exceed your expectations. The combination of our engineering expertise, problem-solving capabilities, and commitment to quality makes FORGE the preferred partner for storage tank solutions across a multitude of industries.

Should your project face seemingly insurmountable challenges or stringent deadlines, consider the benefits of working with a team that has a proven track record of success. Contact FORGE to discuss how our expertise can facilitate the realization of your project objectives.

To learn more about our capabilities and how we can assist with your storage tank needs, we encourage you to reach out. Let us demonstrate how FORGE can contribute to the success of your next project.

Bolted Steel Water Tanks: The FORGE Way to Secure Sustainable Water Storage

At FORGE, we understand the critical role water storage plays in the infrastructure of any community or business. That’s why we specialize in providing top-of-the-line bolted steel water tanks designed to meet a wide range of needs with efficiency, durability, and reliability. Let’s dive into the applications, best uses, and the particular benefits of using bolted steel water tanks for potable water storage.

Versatile Applications

Bolted steel water tanks are incredibly versatile, making them suitable for various applications. These applications include storing potable water, providing fire protection services, providing industrial water solutions, and more. 

These tanks offer a reliable solution for storing large volumes of water. Their modular design allows for quick assembly and disassembly, providing flexibility in use and location that welded tanks can’t achieve.

Best Uses in Detail

Potable Water Storage: Bolted steel tanks are coated with materials that meet strict standards for storing drinking water safely. Their sealed design prevents contamination, making them an excellent choice for potable water storage for communities and cities.

Fire Protection: Having a dedicated water supply for fire protection can be a game-changer in emergency situations. Bolted steel tanks can be designed to meet specific fire flow requirements, providing peace of mind and enhanced safety for industrial sites, commercial properties, and residential areas.

Industrial Uses: Industries that require large volumes of water for processing, cooling, or waste management can benefit greatly from the durability and capacity of bolted steel tanks.

The FORGE Difference

Choosing FORGE for your bolted steel water tank needs means selecting a partner dedicated to excellence. Our tanks are designed with the latest technology and materials, ensuring they meet the highest standards of safety, efficiency, and environmental sustainability. With decades of experience in the industry, our team is equipped to handle projects of any scale, from planning and design to installation and maintenance.

What sets FORGE apart is not just our commitment to quality but also our focus on customer service. We believe in building lasting relationships with our clients, ensuring they have the support and expertise they need every step of the way. Whether you’re looking to store potable water for a community, need a reliable solution for agricultural irrigation, or require a dedicated water source for fire protection, FORGE has the expertise and resources to meet your needs.

Why Choose FORGE?

  • Expertise: Our team’s deep industry knowledge ensures your project is in capable hands.
  • Quality: We use only the best materials and the latest technologies to construct our tanks.
  • Service: FORGE is committed to outstanding customer service, from initial consultation to post-installation support.

In a world where water is our most precious resource, ensuring its safe and efficient storage is paramount. Bolted steel water tanks from FORGE offer a secure, sustainable, and cost-effective solution for a wide range of storage needs. Let us help you harness the benefits of this innovative storage solution.

Ready to take the next step in securing your water storage solution? Reach out to FORGE today, and let’s explore how our bolted steel water tanks can meet your needs and exceed your expectations.

4 Benefits of Vertical Standing Seam Panel Insulation Systems

The right insulation system can help you increase the lifespan of your large storage tanks, protecting them from the expansions and contractions that come from temperature changes.

The right insulation can also protect the contents of your tank, especially during the winter, when they might be prone to freezing. In some high-heat environments, the right insulation can also protect the contents of your tank from degrading when temperatures rise above optimum levels.

If it has become necessary to add insulation to your tanks, or if you wish to add insulation to your tanks prior to use, then our vertical standing seam panel insulation systems are often the right choice. Here are four reasons why this is so. 

#1) They’re Easy to Install

Vertical standing seam panel insulation systems can be installed without scaffolding. They don’t require any welding because they use an internal cable and clip system to secure them to the tank wall.

This means they go up quickly, safely, and cost-effectively when compared to horizontal panels, which must be stacked in rings around the tank.

Our standing seam panel insulation systems are engineered to work with all types of tanks, making them a versatile choice regardless of your application.

#2) They’re Easy to Transport

Vertical standing seam panels may be stacked and packed in crates, then transported straight to your job site. They’re smaller, as they are each two feet wide versus 50-foot horizontal panels.

Transportation thus costs far less than it would for other options, as these panels require no special permits and take up less space. 

#3) They’re Extremely Reliable

Vertical panels are less likely to shift over time. They tolerate extreme weather conditions very well. They’ve been designed to maintain a watertight connection regardless of fluctuating temperature conditions. 

#4) Low Ownership Costs

Vertical panels don’t require ongoing maintenance and are moisture-resistant. If a single panel fails, that panel may be replaced without forcing you to install a brand-new insulation system. 

The low-maintenance nature of vertical standing seam insulation panels reduces the costs of owning the panels and the costs of owning your storage tanks as well.

By contrast, horizontal panels require monitoring and tightening of the bands, which secure the panels to the tank in order to prevent buckling.

Schedule a Quote Today 

FORGE can outfit your new tanks with insulation panels on installation or outfit existing tanks. We also offer a choice of panel materials to meet different thermal requirements. We serve most markets where a storage tank would be needed.

Request a quote or get in touch to discuss your options today! 

3 Reasons to Choose FORGE Over Other Tank Providers

You have many options when deciding who will provide your bolted storage tanks. Why choose us over any other competitor?

At FORGE, tanks are more than a commodity, and we look for ways to provide our customers with a superior experience. 

#1) All FORGE Field Supervisors and Construction Technicians are FORGE employees.

Even though most tank companies subcontract, at FORGE, we have our own employee crews and engineers on staff. This means we’re accountable for everything that we do while we’re on your job site and for the results we achieve when we deliver your chosen solution.

It also means that you always have access to experts who answer your questions and care about the success of your project. Plus, we’ve found multiple methods for ensuring installation is faster and more cost-effective than our competitors.

#2) We make your life easier.

We have a track record of delivering tanks to job sites on time, getting them installed on time, and providing a quality, long-lasting install. This reduces costs and headaches throughout the lifespan of every tank that you purchase. 

While we believe remaining on time and on budget are the very baseline of customer service, you’d be surprised at how many bolted tank providers seem to find it impossible to meet this baseline.

We’re the company to call if you want results, not excuses. 

We also look for cost-effective solutions to your problems. If we know a less expensive tank retrofit is going to solve your problem just as well as a new tank install would, then we are going to suggest the retrofit every time. That’s how we’d want to be treated were we in your shoes. 

#3) We do what we say we’re going to do.

We remain focused on doing one thing and doing it well, and thus, we make it easy to do business with us. Current customers would tell you that we keep our promises, and they routinely tell us how easy it is to do business with us.

We know that we’re here to support your business and know that matters to you, perhaps far more than hearing a long list of tank features. While we always provide quality tanks that benefit from the latest and greatest in tank engineering, we know that it takes more than better tank design to make our customers happy.

Forge a relationship with us today! 

We sell tanks, but we forge relationships. Most of our customers stay with us for decades because they know we’ll treat them as more than a dollar sign. If you’d like to experience the difference that comes from working with a company that wants to create a partnership with you, then reach out to FORGE to schedule a call today.

We’ll discuss your application, your needs, the challenges you’re facing, and how we can meet those challenges. 

Mass Flow vs. Funnel Flow in Dry Bolted Tanks

The flow pattern in a bolted tank impacts the discharge rate, material handling efficiency of the tank, and the potential for material segregation within the tank. 

A mass flow tank allows material to flow uniformly across the entire hopper outlet. Mass flow is most appropriate for cohesive materials which require a more uniform discharge. Examples include wet or sticky bulk solids, certain food products, or materials with irregular shapes. 

Funnel flow tanks allow material to flow only through the central part of the outlet. Funnel flow is suitable for free-flowing, non-cohesive materials like powders or dry particles.  Funnel flow can also be helpful when space is at a premium. 

You should also take hopper geometry into account when choosing flow types. You should also consider the angle of repose of the material. Choosing the right flow panels can help you avoid many bulk solids handling problems.

Engineering Flowability

We can engineer different flow patterns when we design a tank for you. For example, a smooth, steep cone helps to facilitate a mass flow pattern. We can also help by designing alternate hopper angles.

Can the flow pattern be changed in an existing tank?

Yes. We will be happy to discuss how we can conduct this project on your behalf. 

How can operators determine the flow pattern in a dry-bolted tank?

You can determine the flow pattern in a dry bolted tank by observing material discharge patterns during operation, conducting flow tests, or consulting with engineers experienced in bulk material handling.

Get Help Today

The team at FORGE doesn’t just design incredible tanks. We also design tanks specifically to help you solve your materials handling and storage problems. We’ll complete your job on time and budget and have plenty of experience helping customers manage their tank-based needs. 

Ready to get started? Reach out and get in touch! 

What is Cathodic Protection in Tanks?

Cathodic protection is a method of controlling corrosion inside storage tanks. You can combine cathodic protection with tank coating to double the lifespan of the coating.

Here is what you should know about these systems before purchasing them as an option for your tank.

 

Is cathodic protection cost-effective? 

Cathodic protection is extremely cost-effective, both because the cost of installation is relatively low and because it can extend the life of the tank coating by as much as 20 years. 

 

How does cathodic protection work? 

Cathodic protection relies on the use of a “sacrificial anode.” A sacrificial anode is a metal that is more reactive than the tank material. 

The anode corrodes instead of the tank metal.

The protection is primarily added to the interior of the tank, which is where the highest risk of corrosion exists.

 

What types of cathodic protection exist?

There are two types.

The first type is galvanic cathodic protection. Galvanic systems use anodes connected in a circuit. Galvanic protection uses the natural difference between the anode and the structure to drive natural currents to the anode. These systems are the most cost-effective and are the ones that the vast majority of our clients choose to use.

The second type is impressed current cathodic protection, which requires an external power source to drive current to the anode. These systems last longer, are easy to monitor, and offer greater system control.

 

Is it possible to retrofit a tank with cathodic protection?

Yes, it is possible. In fact, FORGE does offer an ancillary equipment installation service that would allow us to retrofit your tank for you. 

 

How do you choose the right cathodic protection systems for tanks?

The right protection depends on tank material and tank size, as well as your budget and needs. 

 

How can I make sure my tank has cathodic protection?

Talk to our engineers when you order your FORGE tanks. Our potable water tank systems are engineered and fabricated to satisfy the specifications you give us, including cathodic protection standards.

We are there for you from the design phase to the construction phase and thus can create a comprehensive cathodic protection solution for you. 

Ready to FORGE ahead? Request a quote or get in touch today!