Permastore Construction Guide

CONSTRUCTION GUIDE
for
TANKS AND SILOS
These are guidance notes that cover the mechanics of the various tasks detailed. They only
refer to issues directly connected with the execution of the works. Only authorised
persons/contractors adequately supervised, correctly equipped and trained in all aspects of
the risks involved and the equipment to be used should be employed to carry out this work.
They must also be familiar with the safety data sheets of all products used.
It is the responsibility of the person/contractor undertaking these works to consider each
particular installation, its environment and the specific risks involved.
Whilst every care has been taken to ensure the accuracy of this guide through 1 May 2010,
Permastore shall have no liability for any loss or damage (direct, indirect, special or
consequential) arising out of or in connection with this guide. This guide is subject to
supplementation or change at any time without notice at Permastore's sole discretion. This
guide does not constitute a representation or warranty of any kind in favour of the customer,
and the customer's sole warranty is that which is provided in its sales contract with the
distributor. This guide does not amend or change such sales contract in any way.
Permastore Limited
Eye, Suffolk,
IP23 7HS,
England
Tel
: +44 (0) 1379 870723
Fax
: +44 (0) 1379 870530
E-mail : sales@permastore.com
Doc Ref: P132 Rev 9
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Page 1 of 102
Permastore Construction Guide
LIST OF CONTENTS
PART
SECTION
TITLE
PAGE
FOREWORD
3-6
One
General System Description
7-8
One
Tools and Equipment
9-11
One
Planning
12-14
One
General Construction Information
15-19
One
Sheet Identification
20-21
One
Standard Sealants, Cleaners and Primers
22-23
One
Applications Requiring the use of Silicone Sealants
24-25
One
Tank Fixing Details
26-28
One
Structure Dimensions
29-30
Two
Foundation Design and Sealing Options
31-34
Two
Clamping and Levelling Systems
35-36
Three
Assembly of Tanks From the Base Up
37-39
Four
Assembly of Tanks Using Jacks
40-45
Four
Assembly of Tanks Using Jacks and Starter Ring
46-47
Four
Assembly of Double Skin Tank Sheets
48-50
Five
Annular Tanks
51-52
Five
Backfilled Tanks
53-56
Six
Roof Construction Introduction
57-58
Six
Trough Deck Roof Construction
59-60
Six
20 Stainless Steel Roof Construction
61-63
Six
External Tapered Beam Roof Construction
64-65
Six
External Parallel Beam Roof Construction
66-68
Six
GRP Roof Construction
69-70
Six
Pressure Testing of Roofs
71-72
Seven
Glass-Fused-to-Steel Floors
73-75
Eight
Cones
76-79
Nine
Ancillaries
80-89
Ten
Checklist
90-91
Ten
Low Voltage Testing
92-93
Eleven
Troubleshooting
94-97
Pictures from Tools List in Part One Section 2
A1-A4
Appendix A
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FOREWORD
This Construction Guide is provided by Permastore Limited for its Distributors/Contractors.

Distributors/Contractors are advised to study this guide thoroughly and ensure that their building
crews are properly trained to use the information provided.
Distributors/Contractors are
contractually responsible to their customers for the quality construction of the as built structure.
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Page 3 of 102
Foreword
This Construction Guide is intended as a quick

reference manual for experienced crews trained by
Permastore. It is not intended as a do-it-yourself
manual by end users, as it does not included step-bystep instructions for assembly, installation or
commissioning.
The Guide is correct at the time of going to press. In
the event of any doubt concerning any technical point,
please contact the Sales Office at Permastore.
c)
Do not swallow chemicals and do not use

them in areas where food is consumed. If
any chemicals are ingested, refer to safety
data sheets and seek medical assistance
immediately. Make sure that chemical
products are kept and used out of the reach
of children and animals.
d)
Do not smoke in areas where chemical

products are used, as many of them are
flammable.
e)
Do not inhale chemical vapours or dust.

Use a suitable mask and ensure that the
workplace is adequately ventilated.
Vapours from solvent-based products may
have a cumulative effect over time; they
also tend to build up in enclosed spaces. In
the event of any symptoms, leave the work
area immediately and move into fresh air.
If the symptoms persist refer to safety data
sheets and seek medical assistance.
f)
Ensure that there are adequate facilities for

washing and cleansing the skin and that
appropriate cleansers and barrier creams are
available.
g)
Store chemicals in sealed containers in well

ventilated areas and out of the reach of
children. Do not transfer chemicals from
one container into another unless such
action is called for by the process.
h)
Clean up all spillages immediately.
i)
Except for transport in closed packages or

sealed containers, chemical products should
be handled only by authorised personnel.
j)
Ensure that the correct equipment is

available for handling the chemical
products provided.
k)
If any person handling the chemical

products on the site shows symptoms which
may be caused by exposure to the products,
remove the person from the site, refer to
safety data sheets and seek medical advice.
Health and Safety Requirements

All work described in this guide must be carried out
in accordance with all relevant local health and safety
regulations. In the United Kingdom the Health and
Safety at Work Act 1974 applies. The requirements
for training and instruction of work crews are covered
by Section 2 of this Act. Regulation 3 of the
Management of Health and Safety at Work
Regulations 1992 requires a risk assessment to be
carried out at all sites prior to commencement of
work.
Irrespective of legal requirements, always observe the
following health and safety rules:1.
The Safe Handling of Chemical Products

The chemical products (sealants, primers,
cleaners, etc) needed for the construction of
PERMASTORE tanks and silos must be
handled only by experienced personnel, who
should be adequately supervised by their
employer to ensure that all work is carried out in
a safe and correct manner. Always observe the
following points:a)
b)
Read the manufacturer's instructions on the

container or accompanying safety data
sheet before starting to use the product.
Chemical products must never be allowed
to come into contact with eyes or skin.
Always wear appropriate protective
clothing and eye protectors. Use a barrier
cream on your hands and generally observe
good industrial hygiene practices. Remove
splashes with an industrial hand cleanser,
never use cleaners or solvents to remove
splashes from skin. Persons vary in their
sensitivity to different chemicals. Some
persons react to trace chemicals from
splashes on outer clothing; ensure that
clothing is properly laundered. In the event
of irritation, burns or other symptoms, refer
to safety data sheets and seek medical
assistance.
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2.
Fire and Explosion Risk

Some of the products used on site are flammable.
Vapours given off by some products, when
mixed with air, may be explosive. Therefore:a)
Never use naked flames in the work area.
b)
Do not smoke in the work area.
Page 4 of 102

c)
Avoid the use of spark-producing

equipment (electric switchgear, grinders,
etc) in the work area.
d)
Never use water as an extinguishant. Use

CO extinguishers or dry powder
extinguishers.
e)
Ensure good ventilation in the work area

and keep chemical product containers
sealed when not in use.
f)
3.
Foreword
Store all flammable materials in accordance

with the relevant safety regulations.
Handling Hints
Chemical products used on site may have a
limited shelf life, which is dependent on storage
temperature.
Do not order these products
prematurely, to avoid deterioration. They should
be stored in areas which are cool, dry, well
ventilated and secure. Refer to the
manufacturer's instructions or accompanying
safety data sheet.
Sealants: Can burn if subjected to intense heat
or direct flames. To extinguish burning sealant,
use CO/foam or dry powder extinguisher.
Remove splashes of sealant on skin immediately
with an industrial hand cleanser. Sealants
normally present no inhalation problems given
good ventilation. Scrape up spilled sealant or
drips from excessive application, then wash the
area affected with a strong industrial detergent in
hot water.
Primers and Cleaners: Contain solvents and
are flammable. Use them only in well ventilated
areas.
Do not smoke when using them and keep away
from all naked flames, intense heat or sparking
equipment. To extinguish a fire use CO/foam or
dry powder extinguisher or, in an emergency,
dry sand or earth.
Remove splashes on the skin with an industrial
hand cleanser. Dry the skin with disposable
paper towels, not with a cloth towel.
Solvent vapours, even under conditions of low
rates of evaporation, can quickly build up in
enclosed areas lacking adequate ventilation.
Wear a suitable air mask. If you feel drowsy,
nauseous or if you experience breathing
difficulties, move into fresh air.
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Never dispose of surplus sealants or cleaners into

the drains; ensure their safe removal in
accordance with regulations for the safe disposal
of industrial waste. If primer or cleaner are
spilled, soak up the spillage with dry sand, scoop
the sand into strong polythene bags and dispose
of them in accordance with regulations for the
safe disposal of industrial waste.
4.
Site Safety
All relevant site safety regulations must be
observed. In general, these would include the
following requirements:a)
Wear appropriate safety clothing, including

helmets, masks, goggles, ear protectors,
coveralls, gloves and safety boots.
b)
For work above ground level, use approved

safety harness.
c)
Secure all ladders at the top. In some cases

it may also need to be restrained by an
assistant. If a ladder is not secured and not
in use, it must be laid down.
d)
Scaffolding must be erected in the approved

manner and secured during use. When not
in use, scaffolding must be left secure and
with all means of access removed.
e)
All hand held electric tools and equipment

should be of 110v type.
f)
All plant and electric equipment must be

inspected at regular intervals and faults
must be repaired before further use.
g)
Every installation crew must be provided

with a first-aid kit as standard equipment.
h)
Personnel working on sewage treatment

plants must be protected against leptospiral
jaundice. Infection is usually via broken
skin or cuts, which must therefore be
properly protected. All personnel must be
issued with and must always carry a special
card containing details of their occupation,
the name of their doctor and precautions to
be taken against leptospiral jaundice. This
card must be produced when a visit is made
to a doctor or hospital and those in
attendance must be made aware of the
holder's occupation.
Page 5 of 102

i)
5.
Foreword
Special precautions, such as the provision

of forced ventilation and lifting harness,
must be taken to safeguard personnel
working within a structure which has been
classified as a 'confined space'.
Site Practice
To ensure that all work is carried out to the
required standard of quality, observe the
following rules:a) Tank kits are shrink-wrapped prior to
shipment; they should not be accepted for
delivery to the site more than 4-6 weeks
before commencement of installation.
b) Store kits off the ground and clear of any
surface water. Avoid storing kits in busy
areas where they may suffer damage.
c) Whenever possible, transport the sheets to the
tank site on their original packing skids. Use
care when lifting sheets off the stack.
d) Keep the storage time of sealants to a
minimum, as they have a limited shelf life,
especially at high ambient temperatures.
6.
Safety Awareness Signage

All Safety Awareness signage provided within
the tank construction kit must be installed at low
level in close proximity to entry/access
equipment (eg Access Hatch, Ladder, Staircase,
Walkway etc) ensuring that those who need to
enter or access the structure for inspection or
maintenance purposes are made aware of any
potential dangers.
not fully conversant with these requirements must

contact his local Health and Safety Advisory Board
for assistance. While every care has been taken to
ensure the accuracy of this guide up to the date of
publication, Permastore shall have no liability for any
loss or damage (direct, indirect, special or
consequential) arising out of or in connection with
this guide. This guide is subject to additions,
deletions or changes at any time without prior notice
at the sole discretion of Permastore.
This guide does not constitute a representation of
warranty of any kind in favour of the customer. The
customer's sole warranty is that which is provided in
the customer's sales contract with the distributor of
Permastore products. This guide does not amend,
change or supersede such sales contract in any way.
Registered Trade Names and Copyright
The following trade names, PERMASTORE,
FUSION, ISOFUSION V700, HV ISOFUSION,
TRIFUSION, ECOFUSION, TRIFUSION PLUS
and Fusion Tanks & Silos are the property of
Permastore Limited.
Permastore Limited reserves all copyright in this
guide. Neither the complete guide nor any part of it
may be used without prior permission for any purpose
other than the purpose for which it is issued by
Permastore.
About This Guide

Where necessary, comments on three levels have been
added to the instructions:NOTE: Denotes information of a general or technical
nature which may be found helpful.
CAUTION: Draws attention to actions which may
cause damage to equipment or materials.
WARNING: Highlights risks of accidents or injury
to personnel.
The instructions and notes are intended primarily as a
guide for the proper construction of Permastore tanks
and silos. The cautions and warnings, as well as the
general safety and health rules above, are provided in
the interests of safety. Any person in control of a
construction project or responsible for site safety in
any other capacity must comply fully with all national
and local safety laws and regulations; any such person
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PART ONE Section 1

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The Permastore product is a bolted modular system

for the construction of tanks, silos and similar steel
structures of essentially regular cylindrical form of
diameters from 3.41m to 85.38m (11ft-280ft) and
heights from 1.4m to 29.4m (5ft-96ft) dependent upon
the diameter. Capacities range from 13m3 to over
36,000m3 (2,860gals 7,920,000 gals).
The system comprises essentially high-grade steel
sheets, silo bolts, roof beams and panels, stiffening
and fixing members, as well as a wide range of
ancillaries (manholes, flanges, launders, ladders,
platforms, etc). The steel sheets, which are rollcurved to the radius appropriate for any given
application, are punched with one or several rows of
holes, through which they are bolted together on site.
The sheets are coated on both sides by a special
Glass-Fused-to-Steel vitreous enamelling process for
which
the
trade
names
ECOFUSION ,
ISOFUSION V700,
HV
ISOFUSION,
TRIFUSION and TRIFUSION PLUS are used.

This FUSION family of vitreous enamel provides
cost effective storage solutions in applications from
the storage of agricultural sludges to very demanding
municipal/industrial effluents.
The coating is sprayed and fused onto the specially
prepared sheets at the Permastore plant. Sheets are
tested to confirm continuity of the Glass-Fused-toSteel vitreous enamel coating. For protection during
transport and storage the edges are coated with an anti
corrosive system.
holes. Since each hole must be slightly larger than the

bolt to facilitate assembly, all bolts must be in shear
between sheets when they are tightened. Hence the
importance of ensuring the correct straight shank
length is used. See Part One: Section 7.
Where tanks are provided with Glass-Fused-to-Steel
vitreous enamel floors strict supervision is called for
during construction of the floor and any further work.
The floor should be temporarily protected from
damage which may be caused by footwear and
careless handling of tools.
Following completion of construction the structure
should be swab tested to confirm the continuity of the
internal Glass-Fused-to-Steel vitreous enamel coating.
See Part Ten: Section 2 of this guide. The
application of this test must be witnessed by the
customers site representative following which the 'On
Site Wet Swab Testing Results Chart' (Doc Ref:
02.04.02 Appendix 7) and the 'Certificate of
Completion' (Doc Ref: 02.04.02 Appendix 4) must be
authorised by the Sub-contractor and the customer's
representative.
All tanks, silos and similar storage and process
vessels are subject to containment and environmental
stresses. Each unit is carefully designed to give
reliable performance. You must therefore ensure that
the methods of construction as detailed in this guide
are carefully followed.
In case of doubt, don't guess; ask your employer for
clarification.
The overlap between sheets (both horizontal and

vertical) must be coated with sufficient sealant for
enough to be squeezed out when the bolts are
tightened to allow it to be smoothed into a fillet which
covers the edge of the sheet and extends several
millimetres onto the exposed side of the sheet.
Similarly, bolts and holes must have sufficient sealant
to protect the bore and the shank, and to squeeze out
to form a seal around the bolt head and nut. A bead of
sealant must also be used to seal the nut when plastic
nut covers are utilised.
The proper application of sealant is absolutely
essential for making the tank leakproof. Strict
supervision of the sealing operation can save you a lot
of trouble after completion and testing, when any
leaks will have to be made good.
Another point calling for special attention is the
proper expansion of vertical sheet joints. Although
tanks are nominally straight-sided, each ring
(horizontal course of sheets) is slightly tapered
inward, so that the outer face of one ring can fit
against the inner face of the ring below it. The slight
taper is achieved by the appropriate location of the
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PART ONE Section 2

Tools and Equipment
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Page 9 of 97

SMALL TOOLS AND EQUIPMENT
ERECTION AND TESTING
Tools and Equipment

FOR
The following schedule of small tools is our

recommendation for a single construction crew:Levelling instrument accurate to within 1.5mm
(1/16 inch) (recommend Dumpy or laser level).
See Appendix A Picture No: 1.
26. Plastic floats x 2. See Appendix A Picture No:

7.
2.
Large tape measure capable of measuring radius

of tank.
28. Small tape measure 5m (15ft).
3.
Ratchet spanner.
29. Polyester slings for moving skids and lifting

sheets.
4.
19mm ( inch) A/F impact sockets x 4 (heavy

duty).
1.
5.
Tapered podgers to align holes in sheet, 3mm

(1/8 inch) tapered up to 14mm (9/16 inch)
(recommend Britool pry bars No 219 x 4). See
Appendix A Picture No: 2.
6.
Cold chisel.
7.
Spanner set (open end and ring).
8.
Screwdriver set.
9.
Putty knife x 8.
30. 12.5mm ( inch) bridge

reamer.
See
31. 300mm (12 inch) adjustable spanner.

32. Stilsons. See Appendix A Picture No: 9.
33. 220mm (9 inch) cutting discs x 4.
34. Safety glasses. See Appendix A Picture No: 12.
35. Ear protectors. See Appendix A Picture No 10.
36. Safety helmets. See Appendix A Picture No 11.
37. Safety harness. See Appendix A Picture No 13.
10. Hacksaw and blades.

11. 1m (3ft) spirit level. See Appendix A Picture
No: 3.
12. Lifting hooks for carrying shell sheets.
27. Bolt croppers.
See
38. Gloves good supply. See Appendix A Picture

No 14.
39. Wheelbarrow x 2.
40. Large special socket inch drive for anchor
bolts.
13. Sheet plate carrier.
41. Cleaning cloths.
14. Centre punch.
42. Selection of drill bits 3mm ( inch) to 13mm

( inch).
15. Crowbar 3ft long.

16. Hammer ball peign.
17. Torque wrench to cover range from 14Nm
(10ft-lb) to 70Nm (50ft-lb). See Appendix A
Picture No: 5.
43. Wet sponge continuity detector Elcometer

model 269. See Appendix A Picture No 16.
44. Aluminium mobile scaffold tower.
45. Sealant trowels x 2.
18. Plastic bucket x 6.
46. One set of Allen keys.
19. Marker pens and chalk.
47. String line
20. Mole grips. See Appendix A Picture No: 6.
48. Lock-up tool chest to be kept on site.
21. Tin snips.
49. 2 x 10mm ( inch) shackles.
22. Pliers.
23. Scissors.
24. Broom.
25. Shovels x 2.
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Tools and Equipment
ELECTRICAL EQUIPMENT (ALL 110 VOLTS)

1.
Impact gun inch drive Bosch, Makita,

Dewalt or similar. See Appendix A Picture
No: 15
2.
Extension lead length suitable for site.
3.
Power drill. See Appendix A Picture No: 17.
4.
220mm (9 inch) disc grinder.
5.
Electrical hoist for lifting sheets.
6.
Jig-saw recommend Bosch variable speed (if

holes are to be cut in tank plates) with a selection
of blades to suit above, Bosch type T118B. See
7.
Mobile generator if mains power is not available

for 110v electric tools. See Appendix A Picture
No: 21.
8.
HILTI Hammer Drill plus drill bits to install

anchor bolts.
9.
Single phase 110v Transformer.
LARGE EQUIPMENT FOR SPECIFIC

APPLICATIONS
1.
Concrete vibrator for rebate concrete.

Appendix A Pictures No: 19 & 20.
2.
Small crane, or similar, for the installation of

sheets for tanks 2 rings high and above and for
positioning pallets of sheets strategically around
the tank when construction jacks are the
preferred solution.
3.
Crane to lift roof beams and centre support rings.
4.
Construction Jacks are recommended for the

construction of tanks/silos with roofs and/or
2 rings high and above. (Contact Permastore for
further advice on suitability and usage).
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PART ONE
Section 3
Planning
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Planning
PLANNING
ON ARRIVAL AT SITE
1.
1.
The distributor/contractor should commission a

soil load-bearing test by a qualified soil test
engineer. Copies of the certificate should be
given to:-
The Crew Leader Should:a)
Make contact with the customer and jointly

inspect the site location to ensure that there
are no obvious safety hazards (eg overhead
power cables etc) and that clear access is
available for delivery vehicles and
construction equipment.
The original certificate should be retained in the

distributor/contractor project file.
b)
Study the site plan and soil load-bearing

certificate.
2.
When planning the site layout the customer's

future plans should be taken into account as this
could affect the positioning.
c)
3.
A site plan must be drawn, agreed and signed by

the customer to safeguard against any possible
changes being requested after the installation
commences.
Ensure that the distributor/contractor has

ordered necessary materials. Remember
that materials are not always available at
short notice.
d)
The distributor/contractor should ensure the

availability of the tools and equipment list in
Section 2 of this guide.
Mark out the site and obtain the customer's

signature on the site plan.
Do not
commence operations without this signature
unless you already have a signed copy.
e)
Place and fix a centre post, if installing

foundation/bases.
f)
Check with the distributor/contractor about

soil disposal and who is responsible for it.
g)
Supervise the digging of the foundation

footings, placement of levelling stakes and
reinforcing.
4.
5.
6.
a)
The construction team/crew leader.
b)
The customer.
The distributor/contractor should appoint a

suitably qualified construction team and also
ensure that all plant and materials required will
be on site when required.
One suitably trained person from the
construction team should be made crew leader.
The crew leader should be responsible at all
times for the safe working practices of the crew
operation, as well as ensuring safe site
conditions, correct sequence of work and coordination in general.
a)
The Remaining Crew Members Should:a)
Make a thorough check of the parts box and

sheet pallets against the packing list
provided and report any shortages
immediately to the crew leader.
The
distributor/contractor should immediately
report any shortages so as to prevent delays
at a later stage of the construction.
b)
Do sub-assembly work on ladders and

platform.
The crew leader should:i)
ii)
liaise with the distributor/contractor to

ensure the arrival of plant and
materials;
liaise with the customer to discuss the
site plan and safe site working with
respect to other sub-contractors and
normal site operations;
iii) set a good example to the other

members of the crew.
b)
2.
The crew leader must also be capable of

reading site plans and drawings, and be
conversant with all aspects of erection
work.
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3.
During Construction
Supervision checks should be made:a)
After excavation work is complete and

before pouring concrete, should there be
any indication of the presence of organic
matter such as rotting vegetation or other
foreign objects, work should cease and
expert advice sought.
b)
To check the approved drawings footings

and base dimensions, anchor bolt, structure
bolt positions and any other relevant
measurements.
Page 13 of 97
4.
Planning
c)
Where construction of the tank is on a

previously prepared concrete foundation by
others, the centre point and orientation
datum's must be marked by the customer or
his representative.
d)
After the base ring is complete and before

pouring concrete, the base ring should
conform with the specified levels,
concentricity (fit top angle temporarily) and
be clamped securely.
e)
Following or during construction the

internal
Glass-Fused-to-Steel
coating
should be checked in the presence of the
customer's
representative
to
ensure
continuity. Part Ten : Section 2 of this
guide refers.
After Structure Completion

The structure must be inspected by the
distributor/contractor or his delegated competent
representative in accordance with the
specifications detailed herein. Refer to the
Permastore Inspection and Maintenance Manual
Document Reference P110, as well as
Part Eleven of this guide.
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PART ONE Section 4

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GENERAL CONSTRUCTION INFORMATION

1.
3.
CAUTION: Take care that objects are not

dropped onto any Glass-Fused-to-Steel sheets.
4.
Tanks are assembled using 12.5mm ( inch)

bolts within 14mm (9/16 inch) holes. It is
important that all vertical joints are fully
expanded during construction to prevent
movement under full hydraulic load, failure to do
this can cause leaks and deformed vertical
seams.
5.
For tank sheets above 10mm thick, fully

expanded vertical joints using a tank sheet
hydraulic joint expander assembly. A sheet joint
expander kit is available from Permastore.
6.
When building tanks from the base up it is easier

to assemble rings of sheets working clockwise.
7.
CAUTION
Sheet surfaces must be clean and dry when

sealant is being applied. See Note 2 under
'Standard Sealants and Primers Part 1 Section 6.
Sealant must always be spread to cover the total
area of the overlap to ensure correct sealing.
2.
CAUTION: Glass-Fused-to-Steel sheets will

bend to a natural tolerance but special care
should be taken when handling.
Bolts should be tightened to a torque of 65Nm

(46ft-lb) except through tapered inserts, which
should be tightened to a torque of 32Nm
(23ft-lb).
Failure to conform to this standard may cause
damage to the panels.
8.
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It is essential that the correct length bolts are

used in the correct place during construction.
Always check fixings charts for the bolt sizes to
be used.
9.
Before inserting the structure bolts, ensure

sealant has been applied into and around each
bolt hole as a safeguard against leaks.
12. All ancillary items bolted to Glass-Fused-toSteel sheets such as angles and brackets must be
fully coated with sealant on contact surfaces to
prevent leakage.
13. All levels must always be maintained at + or
1.5mm (1/16 inch).
10. It is essential to fillet all sheet edges, vertical and

horizontal, both inside and outside the structure.
Wherever possible levels should be checked

from within the structure.
11. At all points where an angle overlaps a vertical
joint, tapered inserts must be used.
14. The circularity on all structures must be to the

following standards:Diameter
Circularity
Up to 13.7m (45ft)
6mm ( inch)
From 14.5m to 26.5m

12.5mm ( inch)
(48ft to 87ft)
27.3m
above
(90ft)
and
25mm (1 inch)
Refer to Part One Section 8 for structure

diameters.
Doc Ref: P132 Rev 9
1/5/10
Page 17 of 97
15. The vertical joint and corner assembly

arrangements for each vertical Series 1400 sheet
joint interchanges are shown as follows, the
individual drawings show the sheet relationship
and the general view shows an 'as-built' typical
example when viewed from the exterior of the
structure.
16. Sheet identification stickers, which are placed

near a vertical seam overlap joint, should be
removed before applying sealant.
17. The length of the bolts can be determined by the
colour of the plastic coating on the bolt heads:The plastic capped bolt head is always used on
the inside of the structure.
Standard Bolts:Colour
Black
Grey
Blue
White
Red
Green
Length
(mm)
25
32
38
44
51
64
Length
(inches)
1
1
1
1
2
2
Length
(mm)
51
64
76
Length
(inches)
2
2
3
Special Bolts:Colour
Brown
Mauve
Yellow
Doc Ref: P132 Rev 9
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Page 18 of 97
17. CAUTION:
If Glass-Fused-to-Steel panels
require cutting on site the operation must always
be carried out using a jig-saw type cutter (refer
to Part Eleven Section 1).
19. CAUTION: Do not attempt to cut Permastore

sheets with a mechanical grinder or use on other
parts in the locality of Glass-Fused-to-Steel
where sparks may contact and adhere to the
surface.
18. CAUTION: Do not attempt to cut Permastore

sheets with gas cutting equipment or use on other
parts in the locality of Glass-Fused-to-Steel,
where sparks may contact and adhere to the
surface.
Doc Ref: P132 Rev 9
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Page 19 of 97
PART ONE Section 5

Doc Ref: P132 Rev 9
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Page 20 of 97
SHEET IDENTIFICATION
MATERIAL IDENTIFICATION EXAMPLES
The sheet identification system (ID holes) is visible

externally after construction and the ID piercing
provides a clear indication of sheet thickness, steel
grade and sheet taper.
MATERIAL IDENTIFICATION
Four different hole shapes indicate the grade of steel:-
TAPER IDENTIFICATION
In order to ensure trouble free sheet to sheet assembly,
Series 1400 sheets are produced with a slight taper to
accommodate the horizontal overlap. Dependent on
the sheet thickness and tank diameter one of the
following options will be provided. The absence of
any notch would signify a straight sheet with no taper.
MATERIAL THICKNESS IDENTIFICATION
To indicate the sheet thickness the standard horizontal
bolt holes are used as datum points.
Notch 1
Notch 1 & 2
Notch 1, 2 & 3
Notch 1, 2, 3 & 4
= Taper Reference 14t

"Whole numbers" ie 2mm, 3mm, 4mm etc are

positioned 40mm to the right of the datum point and
the "half numbers" ie 2.5mm, 3.5mm etc are
positioned 40mm to the left of the next datum point.
For examples refer to the drawing.
Doc Ref: P132 Rev 9
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Page 21 of 97
PART ONE Section 6

Standard Sealants, Cleaners and Primers
Doc Ref: P132 Rev 9
1/5/10
Page 22 of 97

STANDARD
PRIMERS
SEALANTS,
CLEANERS
Sealants and Primers

AND
The following list of sealants and ancillary products

represents those most commonly used for the standard
range of applications.
Sealant Colour
The standard utilisation policy for the construction of
all dark coloured tanks, including standard blue and
green tanks, is to use Sikaflex TS Plus Black sealant.
For all light shades of colour including white, grey
and desert tan tanks Sikaflex TS Plus Grey sealant
will be utilised.
Sikaflex TS Plus
NOTE 2: It is recommended practice for GlassFused-to-Steel surfaces to be clean and dry prior to
the application of the sealant. Glass-Fused-to-Steel
panels are wrapped after manufacture to ensure that
they are clean and dry at the time of construction.
When it is necessary to clean the surface use Sika
Cleaner 205 or alternatively, pure xylene,
methylethylketone (MEK) or isopropylalcohol (IPA).
Do not use any solvents or cleaners that might leave a
residue or contain turpentine, white spirits, phenols,
organic acids, surfactants or silicones. If in doubt
check with Permastore prior to use.
Always follow the manufacturer's advice on Health
and Safety and guidelines for application and curing
times.
Used for sheet joints, painted and galvanised surfaces

in direct contact with Glass-Fused-to-Steel panels,
perimeter base fillet type seals and minor internal
repairs. Due to its high performance specification TS
plus is also used for more specialist applications
requiring chemical and temperature resistance.
Sikasil Pool
Silicone sealant used in conjunction with Sikaflex TS
Plus for the internal primary seal for onerous and/or
high temperature applications.
Sikaflex 221
Only to be used in applications where fast cure is an
essential requirement. (Remedial, maintenance etc).
Sikaswell S2
Hydrophilic base seal.
Sikalastomer 710
Perimeter bond breaker used in conjunction with
Sikaflex TS Plus for tanks above 33.2m diameter and
11.2m in height.
Sika Primer 3N
Concrete primer for perimeter base seals.
Sika Primer 210T
Galvanised surfaces on roof top stiffener and floor
foundation angles.
Sika Cleaner 205
General cleaner for Glass-Fused-to-Steel surfaces and
pre-treatment for silicone sealant overpointing.
Permastore Repair Kit Corroless EP
Minor repairs to panel surfaces and sheet edges.
NOTE 1: Sealant and Primers may vary in
accordance with the process design criteria of the
structure.
Doc Ref: P132 Rev 9
1/5/10
Page 23 of 97
PART ONE Section 7

Applications Requiring the use of Silicone
Sealants
Doc Ref: P132 Rev 9
1/5/10
Page 24 of 97

CONSTRUCTION
SEALANTS
1.
2.
WITH
SILICONE
For applications where the operational

temperatures exceed 50 C or the process
conditions are particularly onerous silicone
sealant is used.
The tank is constructed using Sikaflex TS
Plus with the external tank sheet edges over
pointed with Sikaflex TS Plus.
Sheet
surfaces must be clean and dry when the
Sikaflex TS Plus construction sealant is
being applied. See note 2 under Standard
Sealants and Primers Part 1 Section 6.
3.
The Sikaflex TS Plus sealant is applied over

the bolt holes as normal but controlled
around the internally exposed sheet edges to
minimise excess sealant being extruded into
the contact area of the tank.
4.
Use the extruded Sikaflex TS Plus sealant

around the internal sheet edges to form a
small protective fillet.
5.
It is essential to fillet all internal sheets

edges, vertical and horizontal correctly. For
the inside of the tank structure the Sikaflex
TS Plus is over pointed with silicone sealant.
For the outside of the tank structure external
pointing is completed using Sikaflex TS Plus
sealant only.
Doc Ref: P132 Rev 9
1/5/10
6.
Following a minimum period of 24 hours

check that the Sikflex TS Plus internal
sealant is touch dry.
7.
Prior to applying the internal silicone sealant

as detailed above the existing Sikaflex TS
Plus sealant fillet must be cleaned with
cleaner 205.
8.
Over point the internal sheet edge sealant

with silicone sealant as detailed above.
9.
This method of sealant construction will also

be used for Glass-Fused-to-Steel Floors.
10. For foundation perimeter sealing the Sikflex

TS Plus fillet should also be over pointed
with silicone sealant.
Page 25 of 97
PART ONE Section 8

Tank Fixing Details
Doc Ref: P132 Rev 9
1/5/10
Page 26 of 97
To be used in conjunction with the Fixings Chart on Page 26 of this Guide.
Doc Ref: P132 Rev 9
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Page 27 of 97
Doc Ref: P132 Rev 9
Tank Fixing Details
1/5/10
Page 28 of 97
PART ONE Section 9

Doc Ref: P132 Rev 9
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Page 29 of 97
INTERNAL DIMENSION OF STRUCTURES

Nominal Radius
Model
Diameter
Reference
11
14
17
20
22
25
28
31
34
36
39
42
45
48
50
53
56
59
62
64
67
70
73
76
78
81
84
87
90
92
95
98
101
104
106
109
112
115
118
120
123
126
129
132
134
137
140
143
Sheets
Per
Ring
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
Nominal Radius
Metres
Feet and
Inches
1.708
2.135
2.562
2.988
3.415
3.842
4.269
4.696
5.123
5.550
5.977
6.404
6.831
7.258
7.685
8.112
8.359
8.965
9.392
9.819
10.246
10.673
11.100
11.527
11.954
12.380
12.808
13.235
13.662
14.089
14.516
14.942
15.369
15.796
16.223
16.650
17.077
17.504
17.931
18.358
18.785
19.211
19.638
20.065
20.492
20.919
21.346
21.773
5'
7'
8'
9'
11'
12'
14'
15'
16'
18'
19'
21'
22'
23'
25'
26'
28'
29'
30'
32'
33'
35'
36'
37'
39'
40'
42'
43'
44'
46'
47'
49'
50'
51'
53'
54'
56'
57'
58'
60'
61'
63'
64'
65'
67'
68'
70'
71'
7"
4"
9"
2"
7"
"
4"
9"
2"
7"
"
4"
9"
2"
7"
"
5"
9"
2"
7"
"
5"
9"
2"
7"
"
5"
9"
2"
7"
"
5"
9"
2"
7"
"
5"
10"
2"
7
"
5"
10"
2"
7"
"
5"
Model
Diameter
Reference
146
148
151
154
157
160
162
165
168
171
174
176
179
182
185
188
190
193
196
199
202
204
207
210
213
216
219
221
224
227
230
233
236
239
242
245
248
251
254
257
260
262
265
268
271
274
277
280
Sheets
Per
Ring
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
Metres
22.200
22.627
23.054
23.481
23.908
24.335
24.762
25.189
25.616
26.042
26.470
26.896
27.323
27.750
28.177
28.604
29.031
29.458
29.885
30.311
30.738
31.166
31.593
32.020
32.447
32.873
33.300
33.727
34.154
34.581
35.008
35.436
35.863
36.290
36.717
37.144
37.571
37.998
38.425
38.851
39.278
39.705
40.132
40.559
40.986
41.413
41.840
42.267
Feet and
Inches
72'
74'
75'
77'
78'
79'
81'
82'
84'
85'
86'
88'
89'
91'
92'
93'
95'
96'
98'
99'
100'
102'
103'
105'
106'
107'
109'
110'
112'
113'
113'
116'
117'
119'
120'
121'
123'
124'
126'
127'
128'
130'
131'
133'
134'
135'
137'
138'
10"
2"
7"
"
5"
10"
2"
7"
"
5"
10"
3"
7"
"
5"
10"
3"
7"
"
5"
10"
3"
7"
"
5"
10"
3"
7"
"
5"
10"
3"
8"
"
5"
10"
3"
8"
"
5
10"
3"
8"
"
5"
10"
3"
8"
For tank diameters larger than those charted above please contact Permastore for further advice.
Doc Ref: P132 Rev 9
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Page 30 of 97
PART TWO Section 1

Foundation Design and
Sealing Options
Doc Ref: P132 Rev 9
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Page 31 of 97

FOUNDATION
OPTIONS
1.
DESIGN
AND

SEALING
Ring Beam and Infill Design

Generally considered to be the least complex
design and favoured where the installation team
has responsibility for the base and tank
construction.
The ring beam can be installed prior to arrival of
the tank kit on site and the foundation bolts
positioned whilst the concrete is still wet, if
required.
The base slab (infill) is generally poured
following construction of the starter or base ring.
Alternatively it is poured following completion
of the tank shell if the structure is being built
using construction jacks.
Rebate Base Design

Utilised mainly where the base design and
construction is by a third party, it facilitates a
proven concept to achieve effective hydrostatic
containment where two separate contracting
agents have responsibility for a common
workface.
2.
Flat Base Design

Generally as (2) overleaf, but requires a very
high standard of base concrete construction to
achieve an acceptable level and flatness.
It is essential that these levels of workmanship
are attained to enable the tank to be successfully
constructed and sealed.
This concept has a limited range of use and is
only recommended for experienced installation
teams.
TANKS UP TO AND INCLUDING 8 RINGS HIGH
TANKS UP TO AND INCLUDING 8 RINGS HIGH
TANKS ABOVE 8 RINGS HIGH.
TANKS ABOVE 8 RINGS HIGH
Doc Ref: P132 Rev 9
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Page 32 of 97

BASE PERIMETER SEAL OPTIONS
1. Perimeter Fillet Seal
a)
Pour concrete to the level specified on the

drawing or level with existing foundations.
Ensure that the concrete completely fills the
gap between the ring beam or floor slab and
the base angle.
NOTE: It is recommended that a concrete
vibrator is used to ensure that the concrete
fully flows beneath and around the base
angle.
LIMITED TO TANKS WITHIN THE RANGE

3.4M (11FT) 16.2M (53FT) DIAMETER AND
1 RING - 6 RINGS HIGH
b)
When the concrete has cured sweep clean

the perimeter of the foundations inside the
tank to remove any surface debris.
c)
Clean the Glass-Fused-to-Steel surface

immediately above the concrete level inside
the tank to ensure good adhesion for the
sealant fillet. See Note 2 under 'Standard
Sealants and Primers' Part 1 Section 6.
d)
Apply primer to the concrete base only

extending
approximately
50-60mm
(2 inches) inwards from the tank wall.
e)
Review the instructions for use of the

perimeter sealant being used and then apply
the sealant.
f)
Allow to cure as manufacturer's instruction.
4. Agricultural Slurry Tank Base Design

Identical to Ring Beam and Infill design with the
exception that case-in anchor bolts are always
supplied.
TANKS UP TO AND INCLUDING 6 RINGS

HIGH
Doc Ref: P132 Rev 9
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Page 33 of 97
2. Perimeter Fillet Seal with Bond Breaker

for tanks above 33.2m diameter and 11.2m
in height.
a) Pour concrete to the level specified on the
drawing or level with existing foundations.
Ensure that the concrete completely fills the
gap between the ring beam or floor slab and
the base angle.
NOTE: It is recommended that a concrete
vibrator is used to ensure that the concrete
fully flows beneath and around the base
angle.
b) When the concrete has cured sweep clean the
perimeter of the foundations inside the tank to
remove any surface debris.
c) Clean the Glass-Fused-to-Steel surface
immediately above the concrete level inside
the tank to ensure good adhesion for the
sealant fillet. See Note 2 under 'Standard
Sealants and Primers' Part 1 Section 6.
d) Apply primer to the concrete base only
extending approximately 50-60mm (2 inches)
inwards from the tank wall.
e) Apply the perimeter bond breaker as detailed
and ensure it is touch dry and then apply the
perimeter seal fillet.
f) Allow to cure as manufacturers instructions.
Doc Ref: P132 Rev 9
1/5/10
Page 34 of 97
PART TWO Section 2

Tank to Base Clamping and
Levelling Systems
Doc Ref: P132 Rev 9
1/5/10
Page 35 of 97
Clamp and Levelling Systems

NOTE: Always maintain an even adjustment
of the levelling plates.
ANCHOR BOLT AND CLAMP

1.
Brush clean the top surface of the ring wall.

Mark out the tank radius on the concrete surface.
2.
Place shims inside each anchor bolt at the correct

radius from the centre point of the tank.
Check the levels of the shims to within 1.5mm
(1/16 inch).
2.
From the tank centre stake mark out the

foundation angle radius on to the levelling plates.
Place the foundation angles round the tank
circumference, on top of the levelling plates,
ensuring that when sheets are fitted, vertical
seam joints are adjacent to a levelling system,
with another levelling system situated mid sheet
and all are equally spaced.
3.
3.
There must be a minimum gap of 25mm (1 inch)

between the foundation angles and foundation
concrete.
Fit the hold down clamps onto the outer anchor

bolt and foundation angle and loosely tighten,
whilst checking that the correct radius is
maintained.
4.
It is essential that anchor clamps are clamped

directly onto a shim pack.
THROUGH ANGLE FIXING (EMBEDDED AND

FLAT BASE TANKS)
1.
For Through Angle fixing the base angle will be

supplied pre-punched to identify the location of
the anchor bolts. Position of bolt holes to be
used is shown on construction drawings.
2.
For applications where the tank is constructed

from the base ring upwards (stack building) the
foundation bolts are installed following
completion of the base ring. For applications
where the tanks are constructed using jacks the
foundation bolts are installed following
completion of the final ring of sheets (base ring).
3.
It is essential that shim packs are located in close

proximity to the foundation bolts and PVC
isolation washers are fitted.
LEVELLING SYSTEM
1.
Using a Dumpy level (or similar) check that all

the levelling plates are installed to within 1.5mm
(1/16 inch), whilst always maintaining a minimum
of 25mm (1 inch) gap between the foundation
concrete and the underside of the base angles.
Tighten the levelling plates.
Doc Ref: P132 Rev 9
1/5/10
Page 36 of 97
PART THREE
Section 1
Assembly of Tanks
From the Base Ring Upwards
Doc Ref: P132 Rev 9
1/5/10
Page 37 of 97
Assembly Methods
ASSEMBLY OF TANKS AND SILOS FROM

THE BASE RING UPWARDS
7.
SPECIAL NOTE: If the levels or the

concentricity are not maintained, problems
will occur when building higher rings,
especially the final stiffener angles.
The Base Ring of Sheets

1.
Refer to bolt charts for correct bolt placement

and assembly.
2.
Apply sealant to the inside face of the foundation

angles and proceed to fit the foundation sheets
ensuring that angles are fitted with an equal
overlap from each vertical joint and tapered
inserts are fitted at the vertical joint positions of
the foundation angles.
See Note 2 under
'Standard Sealants and Primers' Part 1 Section 6.
Fit all remaining base sheets.
Diameter
Circularity
Up to 13.7m (45ft)
6mm ( inch)
From 14.5m to 26.5m
12.5mm ( inch)
(48ft to 87ft)
27.5m (90ft) and
25mm (1 inch)
above
8.
After the vertical joints are fully expanded top

and bottom fit the two bolts left out for this
operation and tighten to correct torque.
NOTE: Check the concentricity of the structure
at this point.
9.
3.
4.
Working in a clockwise direction around the

circumference, apply sealant to the inside face of
the vertical overlapping sheet seam ensuring all
bolt holes are covered.
Leaving out 2 bolts from each vertical seam (the
top bolt and the bolt positioned 5 up from the
bottom), install all remaining bolts checking that
sealant has been applied over each bolt hole
before inserting the bolts.
Tighten all bolts to 65Nm (46ft-lb) torque with

the exception of bolts through tapered inserts,
which should be tightened to 32Nm (23ft-lb)
only.
10. Remove the temporarily fitted top stiffener

angles.
11. Using a pointing trowel, fillet off the vertical
seam sealant as shown below.
SPECIAL NOTE: It is essential that top

angles are fitted temporarily to maintain the
tank shape. Bolt the angles to the top of the
ring of sheets, without sealant, using 6 bolts
equally
spaced
and
tightened
to
25Nm (18ft-lb).
5.
Before tightening the bolts in the vertical seam

ensure that it is fully expanded using the 2 bolt
holes previously left for this operation (see Note
4 above).
6.
For tank sheets above 10mm thick, fully expand

vertical joints using a tank sheet hydraulic joint
expander assembly. A sheet joint expander kit is
available from Permastore.
12. We recommend the installation of an expanding
peripheral waterstop as shown on the project
base drawing.
Doc Ref: P132 Rev 9
1/5/10
Page 38 of 97
Assembly Methods
INTERMEDIATE RINGS
1.

and assembly.
2.
Build the second ring of sheets using suitable

lifting equipment.
3.
Mark all structure holes for the wind stiffener

clip angles with chalk before assembling the ring
of sheets. As the sheets are constructed fit the
clip angles at the same time as the structure bolts
are installed.
7.
Before tightening a partially completed ring,

ensure the end sheets are truly vertical, as these
sheets tend to lean.
8.
Apply sealant fillets to cover sheet edges on

vertical and horizontal joints inside and outside
the tank.
9.
Remove the temporarily fitted top stiffener

angle.
FOUR CORNER JOINT VIEWED FROM

EXTERIOR OF TANK
SPECIAL NOTE: It is essential that top
angles are fitted temporarily to maintain the
tank shape. Bolt the angles to the top of the
ring of sheets, without sealant, using 6 bolts
equally spaced and tighten to 25Nm (18ft-lb).
4.
Fully expand
concentricity.
vertical
joints
and
check
5.
For tank sheets above 10mm thick, fully expand

vertical joints using a tank sheet hydraulic joint
expander assembly. A sheet joint expander kit is
available from Permastore.
6.
Tighten from the centre of each sheet to either

corner on the horizontal seams; tighten the
vertical seam from the corner joint to the top
ensuring that the seam is expanded.
10. All bolt heads are to have a sealant squeeze out

and the 4 corner joints should be completely
covered with sealant.
NOTE: If possible, do not start a new ring of

sheets late in the day if only a small number of
sheets will be completed. Where it is not
possible to complete a full ring of sheets by the
end of the day, secure each end of the unfinished
ring with ropes to prevent any possible overnight
wind damage.
Doc Ref: P132 Rev 9
1/5/10
Page 39 of 97
PART FOUR
Section 1
Assembly of Tanks and Silos

Using Construction Jacks
Doc Ref: P132 Rev 9
1/5/10
Page 40 of 97
Assembly Methods
ASSEMBLY OF TANKS AND SILOS USING

CONSTRUCTION JACKS
k)
Jacks are generally used to construct tanks and

silos which are 3 rings high and above. They are
also regularly used to construct structures with
roofs or starter rings. (Contact Permastore for
further advice on suitability and usage).
l)
Permastore construction jacks are regularly

maintained and load tested. Copies of test
certificates are available to confirm suitably.
Important Information
a)
Permastore construction jacks are designed to

build only Permastore structures.
b)
The construction jacks must only be operated by

trained and competent personnel.
c)
The jacks must not be used when wind speeds

exceed 25mph (40km/hr). If the wind speed
approaches this figure the structure should be
lowered and anchored down to the base. Special
care is needed when gusting winds can exceed
this figure.
d)
e)
f)
h)
Before Commencement of Work

1.
With jacks vertical, check gearbox oil is up to

level plug. (Use EP90 or equivalent).
2.
NOTE: For c) & d) above, ensure that

anchors are removed prior to jacking.
Check splines on gearbox and PTO shafts for

wear or damage and ensure that locking pins are
free and oiled. Grease splines on both and
ensure PTO shaft guards are fitted correctly.
3.
An electrically driven 'Master Jack' drives the

jack units via PTO drive shafts.
Examine motor couplings and drive shaft splines

for wear and check motor/gearbox alignment.
4.
Check all turnbuckle threads are free and oiled

and stays are in good condition.
5.
Examine jack carriage assembly for damage or

wear and oil jack drive screw.
The structure should be lowered and anchored

each evening in case of overnight winds.
Standard operation is for one jack per vertical

seam of the structure with one master jack. For
certain applications slave gearboxes are available
to reduce the requirement for standard
construction jacks (see page 45). Extra jacks
may be used and extra master drive jacks
required for special structures.
It is recommended that jacks be used on both
seams adjacent to platforms and similar heavy
ancillaries.
g)
CONSTRUCTION JACK MAINTENANCE
Before setting up the jacks it is essential to

ensure that they stand on a firm, level
foundation. The jack bases must be level to
prevent overloading of individual jacks and to
ensure that the structural load is evenly
distributed across all of the jacks.
The jacks must be positioned vertically, fixed to
the concrete base using the foundation bolts
provided or clamped to the bottom sheet/angle
and supported by centre and side stays. Centre
and side/top stays must be utilised on every
installation.
Special length top stays are
provided for use with Slave Gearboxes.
i)
The jack spacer plate must be used between the

carriage and structure sheet.
j)
Ensure that electricity supply cables cannot be

accidentally damaged or cut, cover over if
necessary.
The use of armoured cable is
recommended.
Doc Ref: P132 Rev 9
1/5/10
Daily Checks
1.
Check jack lifting carriage assemblies for

damage and security.
2.
Check jack retaining clamp for tightness.
3.
Examine jack support stays and pins and check

jacks for being upright with masons level.
4.
Make sure that jack lifting bolts and nuts are

always in good condition. Any replacement
bolts must be to the correct grade and shank
length. (Minimum Grade 8.8).
Weekly Checks
1.
Jack gearbox oil levels.
2.
Grease rollers on rear of jack carriage plate.
3.
Grease PTO shaft universal joints.
4.
Oil jack drive screws.
NOTE: Ensure that all jacking equipment is kept

clean and in a serviceable condition during the
construction period.
After construction is complete, fully examine all parts
for wear and lubricate before packing away.
Page 41 of 97
Assembly Methods
TYPES OF CONSTRUCTION JACK
3.
Within our stock of construction jacks that are

available for hire we have two distinctly different
models.
1.
Slave Gearboxes
One advantage associated with the low-level
jacks is the opportunity to utilise 'slave
gearboxes' for a specified range of applications.
Slave gearboxes are low cost units that allow
safe construction utilising a reduced number of
jack legs.
High Level Gearbox

The high-level gearbox jacks have the gearbox
and transmission shafts located at the top of the
jack body and have a swivel mounted base plate
for conical foundations. The high level jacks are
tested for a safe working load of six tonnes
(13,200 lbs).
The advantage being more cost effective use of

the jack legs by reducing the amount required to
construct a specified vessel and facilitating
increased use of a limited number of high cost
assets.
Special length top stays are provided for use with
slave gearboxes to ensure positive location of the
assembled equipment. Centre stays and top stays
MUST be utilised on EVERY installation.
A recommended usage chart for slave gearboxes
and low-level jacks is included for reference (see
page 45).
2.
Low Level Gearbox

The low-level gearbox jacks have the gearbox
and transmission shafts located at the bottom of
the jack body and the drive motor is an
independent unit which is floor mounted
between two jacks. The low-level jacks are
tested for a safe working load of four tonnes
8,800 lbs).
Doc Ref: P132 Rev 9
1/5/10
SETTING UP FOR JACK CONSTRUCTION

1.
Set up base angle, level and check concentricity.
2.
Place jacks inside structure on base.
3.
Assemble top row of sheets onto base angle.

Apply sealant to vertical seams only; locate onto
base angle with four bolts per sheet. Expand
sheets and tighten vertical bolts to 65Nm (46ftlb).
4.
Re-check concentricity and clamp down base

angles.
5.
Place jacks at every vertical seam as standard

layout ensuring that they are the correct distance
from the tank wall. For Low Level Jacks the
dimension from inside tank wall to the front face
of the Jack Column should be 140mm and for
High Level Jacks 56mm.
Page 42 of 97

6.
7.
8.
Assembly Methods
Use level to check jack base plates. Pack up

with shims if necessary as the jacks must be on
level base datum to prevent stress during lifting
and possible gearbox damage due to over-run.
Level carriage plates and bolt to sheet using
spacer plates. Make sure that carriage plates are
at their lowest position without fouling the jack
stops.
Fit support struts, check that jacks are vertical
and clamp down with foundation bolts through
the base plates or use clamps.
OPERATION OF JACKS
1.
Jack bolts must be of the correct size and

strength.
2.
Ensure that the jacks are in the low position

before connecting to the sheets and a spacer is
located between the carriage and the sheet.
3.
In all cases a jack bolt must be fitted to every

accessible hole in the carriage plate. A minimum
of three jack bolts must always be utilised.
4.
Loosely tighten the jack bolts and raise the

structure until weight is being taken on the jacks.
Ensure that the jack bolts are located in the
bottom of the carriage plate slots and tighten to
65Nm (46ft-lb) torque.
5.
Raise the top ring of sheets to the correct height

for installation of the next row of sheets or roof.
Install the motor mounting assembly to the

master jack and connect the drive shaft and cover
guard.
CAUTION: Isolate drive motor and remove

drive shaft before commencement of work.
WARNING: When raising the jacks they must
not be run up to the end stops. The carriage plate
must not travel beyond the safe working area.
This will result in damage to the unit and if
persistently abused this could result in failure of
the equipment.
6.
Apply sealant and hang the second row of sheets

in an anti-clockwise direction. Leave out the
bolts at the position the jacks will locate on the
next lift.
7.
Complete a full ring of sheets and fully expand

the vertical seams before tightening.
8.
Fit wind stiffener assemblies where applicable as

full rings are completed.
9.
Loosely pull in any gaps in sheet faces, tighten

from centre to both corners on the horizontal
seam and tighten the vertical seam from the
corner down to the bottom ensuring that the joint
is fully expanded.
CARRIAGE PLATE ASSEMBLY

9.
Fit PTO shaft guards over the universal joint

connections.
10. Check oil levels and lubricate screw thread.
10. When the ring of sheets is complete lower the

structure onto supports until the weight is taken
off the jacks. Remove the jack bolts and spacer
bars and lower the jacks to locate on the next
sheet. Check that the carriage plates jam whilst
lowering.
WARNING: When lowering the jacks they must
not be run up to the end stops. The carriage plate
must not travel beyond the safe working area.
This will result in damage to the unit and if
persistently abused this could result in failure of
the equipment
INSTALLED HIGH LEVEL JACK ASSEMBLY
Doc Ref: P132 Rev 9
1/5/10
11. Repeat the procedure until the structure is

complete.
Page 43 of 97
Assembly Methods
JACK SYSTEM USAGE CHART

(For guidance only)
Series 1400 Low Level System
Each jack leg has a safe working load (SWL) of 4000 kg (8,800 lbs). For small diameter standard tanks use a
jack leg on every vertical seam. For other standard structures up to and including 5 rings high use a combination
of jack legs and slave gearboxes as recommended within the usage chart. Slave gearboxes are suitable only for
structure diameters included within the chart.
For tank diameters outside the scope of this chart including tanks with roofs and any tank in excess of 6 rings high
you must refer to Permastore for advice and confirmation of jack usage.
Sheets Per Ring
(SPR)
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
Model Diameter
(ft)
17
20
22
25
28
31
34
36
39
42
45
48
50
53
56
59
62
64
67
70
73
76
78
81
84
87
90
92
95
98
101
104
Jack Legs
(No of units)
6
7
8
9
10
11
9
9
10
10
10
10
10
10
11
11
12
12
13
13
14
14
15
15
16
16
17
17
18
18
19
19
Slave Gearbox
(No of units)
0
0
0
0
0
0
3
4
4
5
6
7
8
9
9
10
10
11
11
12
12
13
13
14
14
15
15
16
16
17
17
18
Table Continued on Page 46

Doc Ref: P132 Rev 9
1/5/10
Page 44 of 97
Assembly Methods
Table Continued from Page 45

Sheets Per Ring
(SPR)
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
Doc Ref: P132 Rev 9
Model Diameter
(ft)
106
109
112
115
118
120
123
126
129
132
134
137
140
143
146
Jack Legs
(No of units)
20
20
21
21
22
22
23
23
24
24
25
25
26
26
27
1/5/10
Slave Gearbox
(No of units)
18
19
19
20
20
21
21
22
22
23
23
24
24
25
25
Page 45 of 97
PART FOUR
Section 2
Assembly of Tanks and Silos Using

Construction Jacks and a Starter Ring
Doc Ref: P132 Rev 9
1/5/10
Page 46 of 97
Assembly Methods
6.
SETTING UP FOR TANK/SILO

CONSTRUCTION USING JACKS AND A
STARTER RING
Continue
installation
Part Four - Section 1.
as
described
in
Standard base structures may incorporate a starter ring

located onto the base angle. Starter rings are
generally used where a tank/silo may be extended at
some future date. They are also used to progress
installation of the base foundation and can be supplied
in advance of the main tank kit.
Starter Ring
1.
Locate jack support plate (Part No. 512805) at

starter ring vertical seam. Space out with
washers to allow for thickness of base sheet.
2.
Set up construction jacks as standard procedure.
3.
Secure jacks by drilling and rawl bolting through

jack base plate into concrete or use clamps.
4.
Fit structure support brackets (Part No. 523355)

to starter ring.
5.
Hang top row of sheets onto jack carriage plates

using sealant, fit all bolts, expand seams top and
bottom, check circularity and tighten to torque
65Nm (46ft-lb).
Doc Ref: P132 Rev 9
1/5/10
Page 47 of 97
PART FOUR
Section 3
Assembly of
Double Skin Tank Sheets
Doc Ref: P132 Rev 9
1/5/10
Page 48 of 97
Assembly Methods
ASSEMBLY OF DOUBLE SKIN TANK SHEETS

1.
A Permastore Site Supervisor is recommended

for the installation of double skin sheets, unless
the Distributor has prior supervised experience.
2.
Refer to Construction Guide PART THREE

Section 1 for general tank construction guidance.
3.

and assembly.
4.
Ensure double skin sheet assembly rig is

provided and ready prior to construction.
5.
Lift the inner double skin sheet onto the

assembly rig ensuring the sheet is positioned as
shown below.
Outer double skin tank sheet
6.
Apply sealant to the vertical and horizontal bolt

seams and to the outer surface of the inner sheet.
7.
Lift the double skin outer sheet onto the inner

sheet ensuring the holes are aligned as shown in
the view below. Bolt the inner and outer sheet
together using the 8-off bolt holes in the centre
of the sheet.
8.
Lift the assembled sheets into position for the

tank shell construction and apply sealant to the
vertical and horizontal bolt seams of the outer
double skin sheet.
Inner double skin tank sheet
Assembly rig
VIEW OF ASSEMBLED INNER AND OUTER DOUBLE SKIN SHEETS ON ASSEMBLY RIG
Doc Ref: P132 Rev 9
1/5/10
Page 49 of 97
9.
Assembly Methods
Fully expand vertical joints using the double skin

tank sheet hydraulic joint expander assembly. A
sheet joint expander kit is available from
Permastore.
10. The vertical joint and corner assembly

arrangements for double skin and quad row
vertical series 1400 sheet joint interchanges are
shown below as viewed from the exterior of the
structure.
Doc Ref: P132 Rev 9
1/5/10
Page 50 of 97
PART FIVE
Section 1
Annular Tank Construction
Doc Ref: P132 Rev 9
1/5/10
Page 51 of 97
Annular Tank Construction
ANNULAR TANKS
Annular tank systems are generally used for
continuous process applications. They provide a costeffective solution where floor space is at a premium.
The basic concept is two circular tanks of equal
height, one inside the other.
1.
When constructing an annular tank system, first

mark out on the foundation both the inner and
outer tank internal diameters. Also mark a line
from the centre which crosses the internal and
external marked diameters for each of the baffle
walls.
NOTE: Before commencing construction work
check all the relevant drawings for layout
configurations of tanks, especially if they
incorporate launders, baffle walls or revolving
bridges. It is important to ensure the correct
orientation and fitment of all constituent parts.
2.
Construct the inner tank in accordance with the

instructions specified in Part Three or Part Four
of this guide. Ensure the baffle wall fixing holes
are in line with the marked positions. Fit
external stiffener angles as specified on the
arrangement drawing and all exposed fixings on
the exterior of the inner tank must be protected
using the plastic nut caps provided.
3.
Construct the outer tank around the inner tank

taking care to ensure that the baffle wall fixing
positions are in alignment and the datum levels
are consistent with the inner tank.
PLAN VIEW OF TYPICAL ANNULAR SYSTEM
Doc Ref: P132 Rev 9
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Page 52 of 97
PART FIVE
Section 2
Backfilled Tank Construction
Doc Ref: P132 Rev 9
1/5/10
Page 53 of 97

the intersection. Where it is essential that heavy
traffic passes close to the tank or parks close to
the tank for process purposes, the tank should be
backfilled locally with concrete.
BACKFILLED TANKS
Backfilled tanks are designed to be constructed either
wholly or partially below ground level.
IMPORTANT NOTICE:
All work must be
undertaken by competent building crews familiar
with the relevant regulations with particular
regard to Health and Safety. Furthermore, it is
the responsibility of the building crew undertaking
these works to consider each particular
installation, its environment and the specific risks
therein prior to commencement of work, to
determine the protective equipment required by
personnel and to plan the safe system of work that
should be adopted in order for the task to be
carried out safely.
1.
Check all relevant drawings for layout

configurations. It is important to ensure the
correct orientation and fitment of all constituent
parts.
2.
The tank should be constructed in accordance

with the instructions specified in Part Three or
Part Four of this guide.
3.
During construction it is essential that all the

stiffener bands are positioned as shown on the
general arrangement drawing and all exposed
fixings on the exterior of the tank must be
protected using the plastic nut caps provided.
4.
Before the backfill material is laid the tank must

be successfully hydrostatically tested to ensure
complete expansion and as a check on all joints.
The water level must be maintained during
backfilling to prevent possible load damage.
5.
The backfill should be placed in layers 300mm

(12 inches) deep. Each layer must be fully
circumferential. Take care if excavated earth is
being re-used to backfill the tank, this may
contain larger stones or boulders which may
damage the tank. Sand or pea gravel are the
preferred backfill materials but if you are using
local earth then hardboard sheets should be used
to prevent damage.
6.
If the backfill material is to be compacted the

density of the compacted material should not be
greater than the surrounding conditions. Ensure
that machinery used for compaction does not
damage the tank walls.
7.
Unless the tank is specifically designed to such

loads all heavy vehicles or equipment should not
be allowed close to the tank wall. An angle
drawn at 45 from the tank wall/base level gives
Doc Ref: P132 Rev 9
1/5/10
8.
Where tanks are designed to be backfilled with a

fully drained material a positive drainage system
should be provided.
RECEPTION PITS
Important Notice
All work must be undertaken by competent
building crews familiar with the relevant
regulations with particular regard to Health and
Safety. Furthermore, it is the responsibility of the
building crew undertaking these works to consider
each particular installation, its environment and
the specific risks therein prior to commencement
of work, to determine the protective equipment
required by personnel and to plan the safe system
of work that should be adopted in order for the
task to be carried out safely.
1.
Reception pits are available in a range of sizes

up to a maximum 20ft diameter, usually 1 rings
deep. They are mainly utilised in agricultural
applications as gravity fed collection tanks.
2.
For excavation dimensions refer to the approved

reception pit drawings (supplied separately).
EXCAVATE THE PIT AREA

1.
Mark out the perimeter.
2.
Determine the total depth and diameter of the pit

excavation required and proceed with the
excavation, allowing an additional 600mm
(24 inches) on the diameter. Should there be any
risk of soil collapse the excavation area may
have to be increased accordingly.
DANGER: Under no circumstances should
anyone get into the excavation at this stage.
Page 54 of 97
ASSEMBLE THE PIT

1.
The pit should be assembled, above ground, on a

suitable level and firm foundation, ie on an area
of concrete adjacent to the excavated site.
2.
Apply sealant to one vertical and one horizontal

seam only, ensuring the bolt holes are covered.
3.
Start by bolting just the top full ring of sheets

together using the standard overlap right over
left.
4.
Fit the top stiffener angles to the ring of sheets

using tapered inserts at sheet overlap points.
5.
Fit anchor rods at regular spacing as shown on

the approved pit drawing.
13. Check levels and shim until the pit is level to +

or 1.5mm (1/16 inch) with the shims provided
and the top of the pit is to the required finished
height (allowance for pit top or grid to be
included).
14. Place the reinforcing mesh in the base area,
ensuring correct concrete cover by supporting
the mesh with chairs/stools and then pour the
concrete into the pit centre. Ensure that the
concrete flows out underneath the foundation
angles by using a concrete vibrator. Ensure that
levels inside and outside the pit are correct by
referring to the approved pit drawing.
15. Compacted granular fill may be used in the pit
excavation to within 100mm (4 inches) of the
foundation angles, unless the distance between
the edge of the reception pit and the main tank is
less than 2.5m (8ft 3in), when it is then advisable
to backfill with concrete that half of the pit
excavation which is nearest to the main tank.
Determine the amount of compacted granular fill
required, taking into account that all inlet pipes
and anchor rods around the top of the pit are to
be encased in mass concrete. Refer to approved
pit drawings.
Temporarily fit the foundation angles to the pit

without sealant. Use 4 equally spaced bolts per
angle and tighten to 32Nm (23ft-lb).
6.
Tighten all sheet bolts to 65Nm (46ft-lb).
7.
The assembled top ring can now be lifted using

suitable lifting equipment fixed at four equally
spaced points around the pit top. While the pit is
suspended, remove the foundation angles and fit
the lower ring of sheets. Fit the foundation
angles with sealant, using tapered inserts at the
sheet overlap points.
8.
Tighten all bolts to the correct torque.
9.
Fillet all sheet edges both inside the pit and

outside.
10. The assembled pit can now be lowered into the

excavation and should be suspended clear of the
base whilst a crew member goes inside.
11. From inside the pit the crew member should
place concrete blocks in position under the
foundation angle ensuring they are on a level and
firm footing.
12. Check that the pipe opening is set to the centre
line of the main tank and lower the pit onto the
concrete blocks.
Doc Ref: P132 Rev 9
1/5/10
Page 55 of 97
16. When the concrete has cured sufficiently, after a

minimum of 3 days, apply a surface primer to the
concrete base only, as shown, wait for it to
become tack free, then seal inside the pit with a
fillet of sealant between the concrete and GlassFused-to-Steel sheet.
WARNING: Serious damage will result to the

Glass-Fused-to-Steel if a flame torch is used to
dry out base concrete to install the sealant seal.
Doc Ref: P132 Rev 9
1/5/10
Page 56 of 97
PART SIX
Section 1
Roof Construction
Doc Ref: P132 Rev 9
1/5/10
Page 57 of 97
Roof Construction
INTRODUCTION
IMPORTANT NOTICE: All work must be
undertaken by competent building crew familiar
therein prior to commencement of work. To
carried out safely.
As a general rule all roofs should be constructed at
ground level.
Dependent upon the type of roof being installed, site
and
environmental
conditions
and
other
project-specific factors, roofs can be constructed at
varying stages of the installation process.
In some extreme cases alternative methods of roof
construction may affect the roof design.
It is therefore extremely important to evaluate this
subject at the earliest opportunity and plan
accordingly.
The construction methods described within this
section may not apply to all installations.
For advice on alternative methods of construction
please contact Permastore.
Doc Ref: P132 Rev 9
1/5/10
Page 58 of 97
PART SIX
Section 2
Trough Deck Roof Construction
Doc Ref: P132 Rev 9
1/5/10
Page 59 of 97
Roof Construction
TROUGH DECK ROOF CONSTRUCTION

carried out safely.
7.
Position centre row of cladding across tank.

Pilot drill and fix with the self-tapping screws
provided.
8.
Fit rest of cladding working from centre row

outwards. Refer to drawing for special panel
layouts and overlaps. If access is required onto
any area of the roof that has already been clad
then spreader/crawler boards must be utilised
and safety rails fitted along any exposed edges.
Alternatively safety netting can be suspended
underneath the roof.
NOTE: Roofs up to and including 8.53m (28ft)

diameter are constructed at low level before the tank
is jacked to full height. Roofs above 8.53m (28ft)
diameter are generally built following completion of
the tank.
9.
Trim off around edge of top stiffener angle using

a suitable portable nibbler or hand saw.
1.
Study drawing for layout of support brackets,

beam configuration, upright supports etc.
2.
Pre-assemble beams if required.
3.
Fix support brackets to top angle at positions

indicated on drawing.
4.
Fit primary beams and uprights (where required)

ensuring correct location to provide a shallow
fall across the roof.
5.
Fit secondary beams and tie rods if required.
6.
Anchor vertical supports to base.
10. Seal between top stiffener angle and cladding

with aerosol canned foam (where required).
11. Fit perimeter flashing around the tank using the
self-tapping screws provided.
12. Check all coated parts for damage and repair if
necessary.
TROUGH DECK ROOF SHOWING BEAM END AND GRP FLASHING

Doc Ref: P132 Rev 9
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Page 60 of 97
PART SIX
Section 3
20 Stainless Steel Roof Construction
Doc Ref: P132 Rev 9
1/5/10
Page 61 of 97
Roof Construction
20 STAINLESS STEEL ROOF

CONSTRUCTION
carried out safely.
1.
20 Roofs are constructed at ground level.
2.
Assemble top ring of sheets as detailed with Part

Four Section 1.
3.
Set roof cap centre support at the height specific

on the adjacent sketch, dependent on the roof
diameter.
5.
Where special height sheets form part of the

supply these will be specified on the project
drawings.
6.
Fit the centre roof cap onto the roof cap centre
support column.
7.
For roof diameters 6.83m (22ft) and above the

panels are manufactured in two pieces and
panels should be pre-assembled prior to
construction.
8.
The first panel fitted must overlap the sheet

vertical joint by at least one clear hole pitch.
9.
Successive roof panels must be constructed in a

clockwise direction ensuring fitment of the
internal radial stiffener angles as each new panel
is installed.
10. Do not tighten the panels to the roof cap until the
whole assembly is complete.
4.
Variations to tank height can also be calculated

using the combination of sheet heights identified.
Doc Ref: P132 Rev 9
1/5/10
Page 62 of 97
Roof Construction
SPECIAL NOTES
1.
Fit tapered inserts on top of roof panel overlap

points before fixing to underside of roof cap.
Also at the roof panel to tank overlap points and
where the tank shell vertical joints overlap.
Doc Ref: P132 Rev 9
1/5/10
Page 63 of 97
PART SIX
Section 4
External Tapered Beam Roof Construction
Doc Ref: P132 Rev 9
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Page 64 of 97
Roof Construction
EXTERNAL TAPERED BEAM GLASS-FUSEDTO-STEEL ROOF CONSTRUCTION

carried out safely.
1.
Tapered Beam roofs are constructed at ground

level.
2.
Assemble top ring of sheets including the top

angle, as detailed in Part Four Section 1.
3.
4.
Set up suitable load bearing scaffold in the center

of the tank at the correct height to support the
roof during building.
Refer to assembly drawings for positions of
inserts, sealer plates, bolt lengths etc. Roof top
stiffener angle galvanised parts to be primed
with Sika Primer 210T along joint face and
allowed to dry before applying sealant.
6.
When assembling Glass-Fused-to-Steel roof

panels the bolt torque setting should be 65Nm
(46ft-lb) generally and 32Nm (23ft-lb) where
tapered inserts are fitted.
7.
Check that centre support ring is level and set to

the correct height above the top stiffener angles.
8.
Check roof layout for access upstand/flange

positions and walkways and proceed to install
the first four roof beams, placing them at 90
intervals.
9.
Assemble the next four beams in the centre of

the four beams already installed. Proceed to
assemble the rest of the beams using the same
technique.
10. When all beams are in position the roof panels

can be installed.
11. Proceed to fit outer roof panels in an
anticlockwise direction by slackening and
supporting the beams and inserting the panels
between the beam and the top angle, ensure that
the rubber inserts are correctly placed. It is
advisable to assemble at least three panels before
tightening and always leave two loose panels
between the one being installed and the one
being tightened.
12. Following completion of the outer ring of panels
commence installation of the inner roof panels,
again in a clockwise direction.
13. Apply sealant to upper surface of roof panel,
along all bolt seams except at the top (shortest)
edge. With suitable lifting equipment proceed to
lift roof panels into position and fix to under side
of beams installing all bolts in opposite sides of
adjacent beams and lower edge seam.
14. Complete the full ring of panels torque up bolts
in panel previously installed and apply sealant
fillet along the edges of this panel.
15. Proceed to assemble the roof using these
techniques on subsequent rings.
EXTERNAL BEAM ROOF

5.
To assist when hanging very large panels a hole

is punched for attachment of a special lifting
bracket. After fitting the panel apply sealant
around the hole, insert a store bolt and tighten to
65Nm (46ft-lb).
Doc Ref: P132 Rev 9
1/5/10
16. Apply sealant and fit roof cap plates together

with roof cap stiffener.
17. The centre annulus support scaffold must not be
removed until all roof panels are fitted.
Page 65 of 97
PART SIX
Section 5
External Parallel Beam Roof Construction
Doc Ref: P132 Rev 9
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Page 66 of 97
Roof Construction
EXTERNAL PARALLEL BEAM GLASSFUSED-TO-STEEL ROOF CONSTRUCTION

carried out safely.
1.
2.
Paralled Beam roofs are constructed at ground

level.
Assemble top ring of tank sheets including the
top
angle
as
detailed
within
Part
Four - Section 1.
3.
Set up suitable load bearing scaffold in the center

4.
Refer to assembly drawings for positions of

inserts, sealer plates, bolt lengths etc. Roof top
stiffener angle galvanised parts to be primed
with Sika Primer 210T along joint face and
allowed to dry before applying sealant.
5.
To assist when hanging very large panels a hole

is punched for attachment of a lifting bracket.
After fitting the panel apply sealant around the
hole, insert a store bolt and tighten to 65Nm
(46ft-lb).
6.
When assembling Glass-Fused-to-Steel roof

panels the bolt torque setting should be 65Nm
(46ft-lb) generally and 32Nm (23ft-lb) where
tapered inserts are fitted.
7.
Check that centre support ring is level and set to

the correct height above the top stiffener angle.
8.
Check roof layout for start datum and install

starter roof panels. Ensure that rubber inserts are
correctly positioned.
9.
Install first four roof beams, placing them at 90

intervals. Refer to sketches on the following
page for details of beam end attachment.
10. Install next four beams central to the four beams

already installed. Proceed to install the rest of
the beams following the same procedure until all
beams are in position.
11. Following completion of the outer ring of panels
commence installation of the inner roof panels,
again in a clockwise direction.
12. Apply sealant to upper surface of roof panel, ie
along the bolt seams except at the top (shortest)
edge. With suitable lifting equipment proceed to
lift roof panel into position and fix to underside
of beams installing all bolts in opposite sides of
adjacent beams and lower edges seam.
13. Complete the full ring of panels working in a
clockwise direction, torque up bolts in panel
previously installed and apply a sealant fillet
along the edges of this panel.
14. Proceed to assemble the roof using these
techniques on subsequent rings.
15. Apply sealant and fit roof cap plates together
with roof cap stiffener.
16. The centre annulus support scaffold must not be
removed until all roof panels are fitted.
PARALLEL BEAM ROOF
Doc Ref: P132 Rev 9
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Page 67 of 97
Roof Construction
PARALLEL BEAM END ATTACHMENT DETAILS
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Page 68 of 97
PART SIX
Section 6
Glass Reinforced Plastic (GRP)

Roof Construction
Doc Ref: P132 Rev 9
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Page 69 of 97
Roof Construction
GRP ROOF CONSTRUCTION

carried out safely.
1.
GRP roofs are constructed at ground level.
2.
The design and shape of GRP roofs vary

considerably and for this reason the following
instructions are very generalised.
3.
Set up suitable load bearing scaffold in the centre

4.
Using a mobile crane, place first roof panel

positioning the panel onto roof support angles
and centre support scaffold.
5.
Join remaining roof panels together installing

sealer strip or sealant in between joints and bolt
together using the stainless steel setscrews,
washers and nuts provided.
Tighten in
accordance with the manufacturers instructions.
6.
After installing all the roof panels drill out holes

in outer roof support flange to align with holes
already in outer roof support angles. Lift up roof
sheets from roof support angles using a pinch bar
or similar, clean out drill swarf, apply sealant in
between roof support angles and roof flange.
Install store bolts provided and tighten to 30Nm
(20ft-lb).
7.
Place roof cap into position, drill through roof

cap and roof panels with a suitable size drill to
accommodate the fixings provided. Remove
roof cap, clean drill swarf apply sealant, install
fixings provided and tighten in accordance with
the manufacturers instructions.
8.
Do not remove centre roof support scaffold until

all bolts are in position and tightened around the
perimeter of roof and roof cap is correctly
installed.
Doc Ref: P132 Rev 9
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Page 70 of 97
PART SIX
Section 7
Pressure Testing of
Roofs
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Page 71 of 97
Roof Construction
PRESSURE TESTING OF ROOFS

carried out safely.
1.
2.
Where the project specification dictates a

pressurised roof these are designed to withstand
internal pressures and vacuums. Following
construction and hydrostatic testing it is
important to test the roof to ensure that it is
effectively sealed and meets the specified
test/specification conditions.
Equipment needed:-
6.
Use a water and detergent mixture to test all roof

seams and flange connections.
7.
Pressure must be maintained during the period of

test, generally one hour maximum.
8.
Mark any leaks that need to be repaired.
9.
Release pressure from structure and repair any

leaks. If leaks were repaired, re-pressurise and
check they are sealed.
NOTE: It is advised that tests are carried out on
a calm and cloudy day.
Variations in
temperature due to sun, rain or wind can greatly
affect internal pressure. These changes will
cause pressures to fluctuate and will need to be
compensated for during the test.
Extreme fluctuations may cause a serious
over/under pressurisation of roof resulting in
damage if venting is not adequate.
a)
Electric blower
required.
pressure
10. Ensure the roof is vented before draining internal

water to prevent implosion.
b)
Electric extension cables to reach the top of

the structure.
11. When pressure testing to specific test/contractual

conditions it is advisable to ensure the customer's
representative witnesses the test.
c)
Manometer ('U' tube water gauge).
d)
Pipe connection kit.
e)
Appropriate personal safety equipment.
f)
Knapsack sprayer.
capable
of
3.
Seal all tank outlet pipe flanges and access

hatches.
4.
Fill tank with water to operational level.
5.
Install blower connection kit and pressurise roof

to test pressure.
CAUTION:
WHEN
FILLING
AND/OR
DRAINING A TANK IN PREPARATION FOR
OR FOLLOWING ROOF PRESSURE TESTING
IT IS IMPORTANT TO ENSURE THAT ROOF
INSPECTION HATCHES, VENTS, APERTURES
ETC ARE LEFT OPEN TO PREVENT AN
OVER-PRESSURE OR VACUUM SITUATION
OCCURING WHICH MAY RESULT IN
PERMANENT DAMAGE TO THE TANK
STRUCTURE.
ROOF PRESSURE TEST KIT

Doc Ref: P132 Rev 9
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Page 72 of 97
PART SEVEN
Section 1
Construction of
Glass-Fused-to-Steel Floors
Doc Ref: P132 Rev 9
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Page 73 of 97
Glass-Fused-to-Steel Floor Construction
GLASS-FUSED-TO-STEEL FLOOR
CONSTRUCTION
1.
Prior to proceeding with the installation ensure

you have read and understood the layout
drawings for the type and size of floor to be
assembled.
2.
From the centre point of the prepared foundation

mark a circle equivalent to the nominal tank
diameter plus 150mm (6 inches).
3.
Mark out the 0-180 and the 90-270 centre

lines ensuring they are clearly identifiable
outside of the circle.
4.
Lay base angles to confirm location of shim

packs and install shim packs to the CORRECT
radius and level.
5.
Install the bitumen sand (asphalt/tank base)

within the tank circle as detailed on the layout
drawing and level with the shim packs.
6.
Care must be taken to ensure the asphalt surface

is level. A slight rise to the centre is desirable.
7.
Lay polythene sheet and cover asphalt before

installing floor.
8.
Special care must be taken to protect the floor

panels during construction of the floor and tank.
9.
Before each sheet is laid, insert the bolts in

readiness for fitting the adjoining sheets, secure
the bolts with the 'push on' fixing (Part Number
208059091).
12. For Glass-Fused-to-Steel floors above 22.2m

(73ft) diameter and above the perimeter holes
need to be drilled on site.
13. Lay the first panels (row 'D') and ensure that the
first row of floor sheets is in a straight line
before tightening; very important on large tanks.
FLOOR LAYOUT
14. Lay subsequent panels in sequential order as
specified on construction drawing.
15. Fit tapered inserts at the sheet overlap areas
between the floor sheets and the base angles.
16. Fit full rows of sheets before tightening bolts
using the standard torque settings to assist with
alignment.
17. Fillet all sheet edges.
10. Apply sealant ensuring a liberal covering around

the protruding bolts.
11. For Glass-Fused-to-Steel floors up to and
including 21.347m (70ft) diameter the perimeter
holes for fixing the floor to the foundation angles
are pre-drilled.
18. As there is no expansion pressure on a flat

surface it is not necessary to use a joint expander
during construction.
19. For floors up to and including 21.347m (70ft)
diameter that are pre-drilled lay the perimeter
panels first and work inward.
This is feasible due to the circular accuracy of

smaller diameter tanks.
Doc Ref: P132 Rev 9
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Page 74 of 97
Glass-Fused-to-Steel Floor Construction
20. Providing the procedures have been carefully

followed there should not be any cause for
leakage, however, it is advisable for the crew
leader to carefully inspect all areas of the sealing
joints and fillets. This may be your last chance
to ensure a seal.
21. Dependent on the method of construction for the
tank cylinder, protective nut caps should be fitted
now if not using jacks. Where jacks are being
used to construct the tank the nut caps should not
be fitted until after the tank is constructed and all
jack equipment removed.
22. Floor fixings should be treated with Sika Primer
210T and coated with sealant prior to fitting nut
caps.
23. Install the foundation angles and where they join
fit the joint sealer angles (Part Number 559299)
as shown. Floor foundation angles joint faces to
be primed with Sika Primer 210T and allowed to
dry before applying sealant. Construct the first
FLOOR PLATE
BASE ANGLE CONNECTION
26. Continue building the tank structure referring to

the relevant section of this guide.
27. When the structure is complete drill and fit the
foundation bolts and PVC isolation washers and
install the internal perimeter sealant fillet.
ring of tank cylinder sheets in the conventional

manner.
24. Tapered inserts should also be fitted at the
vertical sheet joints.
SECTION THROUGH FOUNDATION BOLT
25. Expand the vertical sheet joints before tightening

the bolts to 65Nm (46ft-lb).
28. Fillet the outside of the structure with concrete if

specified/required.
29. Fit plastic nut caps to the floor area if not already
installed.
30. The finished floor assembly MUST be wet swab
tested at this stage (Part Ten Section 2) and any
repair work undertaken. For details of suitable
repair procedures refer to Part Twelve Section 1
of this guide.
Doc Ref: P132 Rev 9
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Page 75 of 97
PART EIGHT
Section 1
Cone Tank Construction
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Page 76 of 97
Cone Construction
CONE TANK CONSTRUCTION
SKIRT MOUNTED STRUCTURES
IMPORTANT NOTICE:
All work must be
undertaken by competent building crews familiar
regard to Health and Safety. Furthermore it is the
responsibility of the building crew undertaking
therein prior to commencement of work, to
carried out safely.
Introduction
1.
Cones and structures are designed to conform

with the product being stored and customer
requirements. The connection and design
techniques will remain similar.
2.
Except for skirt mounted structures a crane will

be required to lift the structure and cone onto the
supporting steelwork.
3.
Construction layout and techniques are the same

as standard tank design, ie joint overlap and bolt
torque.
4.
A tapered insert is used at angle and sheet

transition overlap areas.
5.
Cone structures are designed to be supported by

Glass-Fused-to-Steel sheets (skirt mounted) or
sectional steel (steel-frame mounted). The actual
design being determined during the enquiry stage
when the operational and storage details are
clear.
6.
Skirt mounted cone structures can, in most cases,

be assembled using the conventional installation
equipment traditionally used to construct
Permastore tank and silos.
7.
Steel frame mounted cone structures generally

require specialist lifting equipment to ensure a
quality and safe construction.
Doc Ref: P132 Rev 9
1/5/10
1.
Build tank structure as standard procedures

ensuring that for the final lift before the hip-joint
the jacks are taken down to their lowest position.
This will ensure the extra height required to
install the hip-joint. Lift jacks to their highest
position and check that clearance is sufficient to
assemble hip-joint and first row of skirt sheets.
2.
Check all relevant drawings and assemble hipjoint leaving out section at jack positions and
ensure that correct length bolts are used, do not
fit those where stiffener ring is to be connected.
Leave bolt finger tight.
3.
Hang first row of sheets leaving out any bolts

where stiffener ring is to be fitted.
4.
Lower structure onto support and disconnect jack

bolts.
5.
Lower jacks and connect for next lift, raise

structure sufficiently to allow completion of hip
joint and fitting first row of cone sheets. After
tightening cone sheets assemble and fit external
stiffener. Raise structure again to hang second
row of skirt sheets.
6.
Continue to build structure adding cone sheet

rings and internal stiffener brackets as required.
Fit internal stiffener on completion of skirt
sheets.
7.
Fit cone outlet adapter to final row of cone

sheets before they are tightened.
Page 77 of 97

8.
Cone Construction
Typical view showing the layout and assembly

of cone structure.
STEEL FRAME MOUNTED CONE

STRUCTURES
1.
These structures are supported below the cone

hip-joints directly onto a steel superstructure and
will require a crane on site, time will be
dependent on method of build.
2.
In most cases the top row of cone sheets would

be assembled on a firm, level area of ground.
Attach the cone support ring and cylinder base
angle.
Doc Ref: P132 Rev 9
1/5/10
3.
Check that the ring of sheets are level, expand

the vertical seams and tighten. Do not tighten
the bolts from the cone support ring to base
angle at this stage.
4.
Lift cone ring with crane using either internal

bracing or a spreader frame to prevent distortion
of the ring. Further rows of cone sheets can be
added at this stage depending on the size of
crane employed.
5.
Lift the cone onto the platform and bolt down.

Tighten all bolts in base angle and channel.
6.
Choose a firm level piece of ground and build

the main structure using construction jacks.
Ensure that the jacks are securely anchored
down. Fit a suitable lifting bracket to each
vertical seam on the top row of sheets.
Page 78 of 97

7.
Cone Construction
Using a spreader bar lift structure onto top of

cone and couple up. Ensure that a good sealant
fillet is applied inside to fully cover the hip-joint
area.
ALTERNATIVE METHODS OF CONE

CONSTRUCTION
1.
The structure can be built by using the crane

instead of construction jacks. Build the top row
of sheets and roof on a suitable level piece of
ground. Fit lifting brackets and install other
rings of sheets while suspended.
2.
Lift pre-assembled structure and couple to cone

at ground level before installing onto steel
platform.
3.
After fitting the cone onto the platform, scaffold

can be placed internally and externally around
the top of the cone and steelwork and the main
structure built directly on top of the cone using
construction jacks. This system will require load
bearing scaffolding and special brackets
manufactured to support the jacks.
Doc Ref: P132 Rev 9
1/5/10
Page 79 of 97
PART NINE
Section 1
Construction of Ancillary Products
Doc Ref: P132 Rev 9
1/5/10
Page 80 of 97
Ancillary Products
GENERAL GUIDANCE NOTES

The ancillary products contained within this part of
the Construction Guide have all been designed by
Permastore or have been technically assessed for
suitability with our standard product.
Although Permastore offer a comprehensive range of
ancillary products there are situations where
customers manufacture their own ancillary products
or where unique process requirements dictate the use
of special equipment, fixtures and fittings.
It is extremely important to ensure the technical
suitability of any ancillary equipment that is not
supplied by Permastore and is to be mounted or fixed
to one of our structures.
The un-necessary
introduction of dis-similar metals for example can
induce an electrolytic cell within the as constructed
tank.
Permastore cannot accept any responsibility for
problems associated with the attachment/fitment of
ancillary equipment by others unless those products
have been approved for use, in writing, by our
Engineering Department.
IF IN DOUBT, ASK.
Doc Ref: P132 Rev 9
1/5/10
Page 81 of 97
Ancillary Products
PROTECTIVE NUT COVERS
FLANGE CONNECTORS
1.
Flange connectors are available in a range of

options, the standard supply is detailed below:-
They can also be purchased separately for

aesthetic purposes if required.
2.
Refer to the assembly drawings for the correct

orientation/position.
2.
Check the relevant drawings for the position of

the protective nut covers (eg backfilled tanks
have nut caps fitted in the area of backfill only,
unless otherwise specified).
3.
3.
Once the nut has been tightened to the final

torque, ensure that there is plenty of sealant
squeeze-out around the nut and washer, then
push the protective nut cover onto the nut and
washer. Use either a rubber or wooden mallet to
install tight caps.
When installing flange connectors, apply sealant

around the sheet aperture where the connector is
in contact with the Glass-Fused-to-Steel plate.
Position the connector and backing flange and fit
the fixing bolts. Tighten fixings to 50Nm (36ftlb).
4.
Fillet the internal edges of the connector

assembly ensuring that the bore is not restricted
by sealant.
1.
4.
Plastic nut covers are supplied as standard with

Glass-Fused-to-Steel floors, backfilled tanks and
inner annular tanks. They are provided to
protect the exposed fixings only where there is a
risk of contents or environmental corrosion.
If the sealant around the nut and washer has

cured, scrape off the cured sealant and apply a
bead of sealant to the inside of the protective nut
cove and push onto the nut and washer assembly.
Doc Ref: P132 Rev 9
1/5/10
Page 82 of 97
Ancillary Products
VENTS AND ROOF HATCHES
TANK WALL ACCESS MANWAYS
1.
Pre-assemble vent or hatch if required.
1.
2.
Apply sealant around roof aperture where the

vent or hatch is in contact with the Glass-Fusedto-Steel sheet. Fit and tighten fixing bolts to
50Nm (36ft-lb).
Tank wall access manways are supplied as a

complete assembly including a pre-cut aperture
sheet and are designed to complement the

particular application required. The standard
manway is 800mm diameter with a hinged cover
to facilitate safe and easy access.
3.
Glass reinforced plastic or aluminium fittings

should only be tightened to 30Nm (20ft-lb).
4.
Steel fitments should be tightened to 50Nm

(36ft-lbs).
5.
Fillet all internal and external edges with sealant.
Doc Ref: P132 Rev 9
1/5/10
2.
Dependent upon the specification supplied it

may be necessary to use a mobile lifting rig to
position the manway frame.
3.
Apply sealant around the sheet aperture inside

and outside the tank, ensuring sufficient
coverage to effectively seal the flange plates.
4.
Position the backing plate inside the tank and

insert a small quantity of fixings.
5.
Position the external frame and fit nuts and

washers to the locating fixings.
6.
Insert the remaining fixings and tighten to the

standard torque setting.
7.
Fillet the internal and external edges of the frame

assembly ensuring effective edge protection.
8.
Position and fix the access door ensuring ease of

operation and effective closure.
Page 83 of 97
Ancillary Products
LADDERS AND PLATFORMS

1.
Ladders and platforms are supplied in various

configurations according to the height, diameter,
market standards and client specification. It is
therefore very important to refer to the assembly
drawing prior to construction to ensure the
correct layout details.
2.
Pre-assemble the ladder platform sections and

mark the position on the tank of the ladder and
platform support brackets.
3.
Ensure the tank bolts have been omitted during

tank construction.
4.
Apply sealant to the tank wall and support

brackets before installing the fixings.
5.
The ladder sections and platform assembly can

then be fitted to the support brackets at low level
as the tank is being built.
6.
Base ladders should be fitted to confirm

suitability but removed before leaving site and
handed to the client for safe storage.
Base ladders should only be
accommodate controlled access.
fitted
to
7.
Install the platform base onto the relevant

support brackets and then complete the assembly
by fitting the upright support and handrails.
8.
Several variations of the standard ladder and

platform options are shown for reference only on
the following pages.
Doc Ref: P132 Rev 9
1/5/10
SECTIONAL VIEW OF INNER AND OUTER

LADDER ASSEMBLY.
Page 84 of 97
Ancillary Products
INDUSTRIAL LADDER AND PLATFORM OPTIONS

OPEN TOP TANK LADDER
ASSEMBLY
Doc Ref: P132 Rev 9
OPEN TOP TANK LADDER ASSEMBLY

WITH OPTIONAL 1M SQUARE
VIEWING PLATFROM
1/5/10
OPEN TOP TANK LADDER ASSEMBLY

WITH OPTIONAL 2M x 1M VIEWING
PLATFORM
Page 85 of 97
Ancillary Products
AGRICULTURAL LADDER AND PLATFORM OPTIONS

OPEN TOPPED AGRICULTURAL TANK LADDER ASSEMBLY WITH OPTIONAL 2M x 1M (6ft x
3ft) PLATFORM WITH CENTRE FLOOR HATCH
5 RING TANK
Doc Ref: P132 Rev 9
4 RING TANK
1/5/10
3 RING TANK
Page 86 of 97
Ancillary Products
CIRCUMFERENTIAL LAUNDERS
1.
Launders are used to remove clarified or settled

liquids from the top of process tanks.
2.
Within our standard range of ancillaries there are

two distinctive systems available.
10. Fit weir plates in position at the correct level

ensuring the sealer strip is effectively placed to
avoid seepage.
'U' TYPE LAUNDER SYSTEM

'Z' TYPE LAUNDER SYSTEM
3.
4.
5.
'Z' type launders are mounted directly onto the

tank wall with a separate scumboard assembly.
Refer to all relevant drawings before
commencement of work to ensure correct
assembly layout. Launder systems should be
fitted at ground level.
Position first launder section at correct height
and central to the outlet flange. Some launders
may incorporate a special dropped outlet. Locate
this section first.
11. 'U' type launders are mounted on brackets with

an internal scum board.
12. Refer to all relevant drawings before
commencement of work to ensure the correct
assembly layout. Launder systems should be
fitted at ground level.
13. Install mounting brackets as detailed around the
perimeter of the tank.
14. Position the first launder section central to the
outlet flange. Some launders may incorporate a
special drop box. Locate this section first.
6.
Where a GRP 'Z' type launder is being installed

drill holes 14mm ( inch) diameter through the
launder trough section using the holes in the
Permastore sheet as a template.
15. Proceed to mount launder trough on the support

brackets around the tank in an anti-clockwise
direction, ensuring that each section is bolted
together with sealant and fixings supplied.
7.
Apply sealant to mating face of launder trough

and Permastore sheet, fit launder in place and
bolt in position.
16. Fix launder trough to mounting brackets using

pre-punched holes, ensuring good sealant
application around fixings.
8.
Proceed to fit launder trough around tank in an

anti-clockwise direction ensuring that each
section is bolted together with sealant and
fixings.
17. Fit weir plates in position at the correct level

ensuring the sealer strip is effectively positioned
to avoid seepage.
9.
The last section of launder trough may need

trimming (GRP only) on the plain section end to
ensure correct joint with outlet section.
Doc Ref: P132 Rev 9
1/5/10
Page 87 of 97
Ancillary Products
BAFFLES AND BAFFLE WALLS

1.
Internal baffle assemblies are utilised to provide

a homogenous mixture of contents in process
tanks.
2.
Directly dependent on the height of the tank the

baffle assembly may be designed as a single
price structure or a modular concept.
3.
Refer to all relevant drawings before

commencement of work to ensure correct
assembly layout. Baffle assemblies and baffle
walls should be installed at ground level.
4.
Apply sealant to the contact surfaces and fit

vertical support angle frames to the tank wall.
5.
Fit Glass-Fused-to-Steel baffle plates to the

angle frame.
2.
Apply sealant to contact faces and fit vertical

support angles to inner and outer tank.
3.
Fit baffle wall to support angles.
4.
Fit top angle to baffle wall using splice plates to

join to inner tank.
5.
After fitting floor angles drill out concrete and fit

expanding anchor bolts.
6.
After completion of baffle walls install concrete

haunch over floor angles if specified.
7.
Apply sealant to contact faces and fit weir weld

assembly to inner tank.
8.
Fit splice plates to weir weld assembly to join to

top stiffener angles.
BAFFLE WALL
1.
Baffle walls are utilised to separate different

sections or processes within a tank.
Doc Ref: P132 Rev 9
1/5/10
Page 88 of 97
Ancillary Products
AGRICULTURAL VALVE KIT (SLUICEGATE)

1.
Refer to approved valve assembly drawings.
2.
When installing the valves and trunking or

pipework, ensure any PVC joints are glued
correctly.
3.
Support the pipe or trunking and valves in the

trench, to allow a minimum of 150mm (6 inches)
concrete cover over the pipework.
4.
Valves must be installed with flow direction

arrow facing the reception pit to ensure that the
valve plate is under flow pressure against the
seal.
5.
Wrap the entire length of PVC pipework in

polythene sheeting.
6.
Care should be taken when pouring the concrete

to ensure the pipework or trunking is not
disturbed or damaged.
7.
Concrete clearance must be maintained at the top

of the valve to allow for top plate removal.
8.
Fitting the outlet into the reception pit may

require the cutting of the Glass-Fused-to-Steel
sheet (Refer to Part Eleven Section 1).
Doc Ref: P132 Rev 9
1/5/10
SACRIFICIAL
ANODE
PROTECTION SYSTEM
CATHODIC
1.
There are some applications where the process

requirements or commercial factors dictate that
routine inspection and maintenance is
impractical.
Where such conditions exist
Permastore recommends that a suitable cathodic
protection system is installed, monitored and
maintained. Cathodic protection systems can
provide a low cost, long term solution to protect
your investment.
2.
For further information please refer to Document

Ref: P145 'Guidance Notes for the Application
and Use of Sacrificial Anode Cathodic
Protection Systems'.
Page 89 of 97
PART TEN
Section 1
Checklist Following Construction
Doc Ref: P132 Rev 9
1/5/10
Page 90 of 97
Checklist
a)
Ensure sufficient sealant has been applied

correctly.
Base ladders removed and stored safely by

the client.
b)
Access doors fitted/closed correctly
a)
To provide full cover to all areas of sheet

overlap;
c)
Pressure test blanking plates removed.
d)
b)
To provide a squeeze out of sealant around

bolt heads, nuts and washers.
No debris/fixings left in the tank that could

damage process equipment.
e)
Any other obvious or client specified

activities.
CHECKLIST AFTER CONSTRUCTION

1.
2.
Have bolts been fitted to all holes used for joint

expansion or jack location?
3.
Have all sheet edges been pointed correctly to

give full protection both internally and
externally?
4.
Have all ancillaries attached to Glass-Fused-toSteel coated sheets been fully coated with sealant
on contact surfaces before being bolted?
5.
Have tapered inserts been used in appropriate

areas at top and bottom angles?
6.
Are the levels and concentricity in accordance

with recommendations?
7.
Are all the bolts within the specified torque

limits?
8.
Has the peripheral base seal been applied

correctly and checked for adhesion?
9.
Are all ancillary items securely fastened?
13. Ensure all packing and waste materials have

been cleared up, disposed of properly and the
site is left tidy. All COSHH substances and
contact packaging must be disposed of in a safe
manner commensurate with the manufacturers
data sheet.
14. Inspect the structure with the customer's
representative and assuming everything is in
order request his authorisation of a Construction
Completion Certificate.
10. Has the full structure been examined carefully

and swab tested internally to identify any
installation damage and have the damaged areas
been repaired? The application of this test must
be witnessed by the customers site representative
following which the 'On Site Wet Swab Testing
Results Chart' (Doc Ref: 02.04.02 Appendix 7)
and the 'Certificate of Completion' (Doc Ref:
02.04.02 Appendix 4) must be authorised by the
sub-contractor and the customers representative.
For full instructions on repair procedures refer to
the Permastore Inspection and Maintenance
Manual Document Reference P110.
11. Check serial plate has been fitted.
12. Check that the Safety Awareness signs provided
within the tank construction kit are installed as
instructed (refer to Item 6, of 'Forward' Section
of this guide)
13. Ensure the structure has been left in a safe and
secure condition for following operations/testing.
For example:
Doc Ref: P132 Rev 9
1/5/10
Page 91 of 97
PART TEN
Section 2
Low Voltage Continuity Testing on Site
Doc Ref: P132 Rev 9
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Page 92 of 97
Testing on Site
LOW VOLTAGE CONTINUITY (WET SWAB)

TESTING ON SITE
All structures should be wet swab tested on the
internal surface following construction.
We recommend that for tall structures being built with
jacks, that a check on the continuity of the internal
Glass-Fused-to-Steel coating is conducted on a ring
by ring basis during construction.
This will identify any minor repairs that may be
necessary following construction and will reassure the
end user that the product has a defect free
containment surface.
It is important to advise the customer's site
representative prior to testing, giving sufficient time
for the test to be witnessed and approved following
completion.
The internal surface of the structure should be clean
and free of surface contaminants. Testing is carried
our using an Elcometer Model 269 Wet Swab Unit set
at 9 volts. The test sponge shall be wet but not
saturated with water containing a small amount of
detergent to reduce surface tension.
In the unlikely event that a discontinuity is found the
following repair procedure should be adopted.
The identified area will be inspected for any signs of
corrosion. Should corrosion be evident the area must
be treated locally with Corroguard, abraded and then
allowed to dry for a minimum of 6 hours and then
overcoated with a 2mm ( inch) thick layer of sealant
overlapping the discontinuity area by 20mm ( inch)
all round.
The area of repair will again be subjected to low volt
test proving satisfactory repair.
Doc Ref: P132 Rev 9
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Page 93 of 97
PART ELEVEN
Section 1
Troubleshooting
Doc Ref: P132 Rev 9
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Page 94 of 97
Troubleshooting
inside of the structure) and cover the bolt
head area of the sheet liberally with sealant.
TROUBLESHOOTING
Introduction
This section has been compiled to assist the
construction team to resolve minor assembly issues
and undertake replacement or modification work.
One of the features of a Glass-Fused-to-Steel bolted
construction tank is the ability to modify the structure
on site to accommodate new or changed process
conditions. It is also possible to extend some
structures in height using either a top or bottom
extension but in all cases reference should be made to
Permastore to ensure suitability of proposed change.
2.
c)
Re-insert the bolts and tighten to the

prescribed torque. Replace the internal
sealant fillet and repoint.
d)
Should the leak be serious, ie more than a

dribble, it may be necessary to part the
sheets with a small hard wooden wedge and
insert sealant to the complete overlap area
with a pallet knife.
Corner Joint Leaks

a)
Remove existing sealant around the corner

joint extending beyond the nearest bolt in
all four directions.
b)
Remove the corner bolt completely and

slacken the four bolts immediately
surrounding the corner bolt.
c)
Wedge open the joint internally with a hard

wooden wedge and inject sealant into the
open joint.
d)
Repeat point (c) externally.
e)
Replace the corner bolt, nut and washer.
LEAKAGE REPAIRS
f)
WARNING: If the structure has been in use there

may be potential hazards from toxic gases or
substances.
Tighten the corner and four surrounding

bolts to the specified torque.
g)
Re-point the corner joint and surrounding

seams with new sealant.

carried out safely.
Please refer to the Health and Safety information

included within the Foreword of this guide.
In the unlikely event that leaks are in evidence on the
structure it may only be possible to effect a reseal
from the inside. The structure must then be drained
completely and the affected area thoroughly dried
before commencement of repair.
NOTE: Should the leak appear on the outside at a
bolt, the source of the leak is not necessarily at the
bolt head but may start through the sheet overlap.
Should the leak appear on the outside at a sheet
overlap the source of the leak is not necessarily at the
same point of the sheet overlap but may start from the
bolt head.
1.
3.
Perimeter Seal Leaks

If the leak is from the base area, again remember
that the point of the leak showing externally is
not necessarily the source and may start from
any point of the perimeter seal up to 3m (10ft)
from the leak. The source may also be from an
area of the floor because of porous concrete. For
perimeter seal leaks:a)
Check the adhesion to the tank wall and

concrete foundation.
b)
Suspect areas should be cut away 500mm

(18 inches) either side of the affected area
and the concrete cleaned and dried.
c)
Apply concrete primer as specified for each

type of perimeter seal.
d)
Apply new sealant to the area cut away.
Bolt or Seam Leaks

a)
b)
To repair, mark the point of the leak

precisely on the outside of the tank before
draining the tank.
After draining the tank remove completely
all structure bolts and internal sealant fillet
within 150mm (6 inches) of the leak. Insert
fresh sealant into the bolt holes (from the
Doc Ref: P132 Rev 9
1/5/10
NOTE: For all sealant repairs allow a minimum

of 10 days to cure before refilling the tank. For
temperatures below 15C an extended cure
period will be required.
Page 95 of 97

REMOVAL OF FLAT SPOTS ON
CORNER JOINTS OF A STRUCTURE
Troubleshooting
THE
DRILLING AND CUTTING HOLES IN GLASSFUSED-TO-STEEL SHEETS
1.
Remove all bolts surrounding the four corner

joints, clean, apply new sealant in the joints and
loosely install new bolts.
WARNING: Do not use disc grinders or flamecutting equipment to cut holes in Glass-Fused-to-Steel
sheets. Always use electric drill and jig-saw.
2.
Secure a wooden support inside the tank with a

M10 ( inch) diameter eye bolt through bolt
hole in sheer joint and pull out flat spot to the
correct shape of the tank. This is best done using
a chain block or similar anchored to a suitable
pulling point. After pulling out flat spots tighten
bolts to the correct torque. Remove chain block,
replace eye bolt and apply sealant fillets to blend
in with the existing fillets.
Always use eye protection when cutting or drilling

sheets.
REMOVING AND REPLACING A GLASSFUSED-TO-STEEL SHEET
Mark the position of the hole to be drilled and dot

punch the centre. Start with a small pilot drill and
gradually increase the drill size to the required size to
the required hole diameter.
WARNING: If the structure has been in use there

may be potential hazards from toxic gases or
substances.
1.

DRILLING HOLES
CUTTING OPENINGS
1.
Apply masking tape over the areas of the

openings to be cut. Mark out the opening and
dot punch the inside edge. Drill out to 10mm
(13/32 inch) and using a jig-saw cut around the
marking opening. Recommend Bosch blades
type T118B.
2.
After cutting or drilling remove all traces of

swarf and burred edges.
3.
Ensure that all edges have been covered with

sealant on completion of work.
Set up scaffold to a working height on the

outside and inside of tank adjacent to where
sheet is to be removed.
To remove the sheet, carefully take out all the
sheet fixing bolts from the sheet overlaps. It
may be necessary to remove the bolts on
adjoining sheets at the four sheet overlap joint
for the distance of about 300mm (12 inches).
Using wooden wedges gently prise the sheet
joints apart. Using suitable lifting equipment
remove tank sheet. Thoroughly clean sealant
from the sheet overlap joints.
2.
If the structure has been in use there may be potential

hazards from toxic gases or substances.
To fit replacement tank sheet, sealant must be

applied to all the overlap faces and with wooden
wedges prise a gap between the adjoining sheets
as with removal. When the replacement sheet is
lowered into position with suitable lifting
equipment, ensure sealant is applied between the
prised open joints and applied to the replacement
bolts before fitting.
PERMASTORE
REPAIR
INSTRUCTIONS FOR USE
KIT
1.
Corroless EP is a two part glass reinforced rust

stabilising primer.
2.
Surface Preparation
Steel should be clean and free from any loose
Glass-Fused-to-Steel coating, oil, grease or rust.
Abrade the surface and surrounding 25mm (1
inch) of sound Glass-Fused-to-Steel with
medium grit emery cloth.
When all bolts are fitted tighten to the standard

torque and apply sealant fillets over sheet edges
to blend in with the existing fillets.
Doc Ref: P132 Rev 9
1/5/10
Page 96 of 97

3.
Troubleshooting
Mixing and Application
5.
Mix the two components at a 1:1 ratio and apply

without delay using a small, clean brush. Ensure
that the material overlaps onto the abraded
Glass-Fused-to-Steel. Do not over brush.
Precautions normally taken when handling

chemicals should be observed. The material
must not come into contact with foodstuffs or
food utensils. The use of protective clothing,
goggles, barrier cream and rubber gloves are
required. Adequate ventilation of the work area
is recommended. Leaflets are available on the
handling of these materials and we strongly
advise they are read prior to using the products.
Externally applied repairs should be over painted

the next day with locally sourced enamel paint to
match the Glass-Fused-to-Steel.
Internal repairs should be covered the following
day with the build sealant. Ensure the sealant
completely covers the repair material and
extends a minimum 20mm ( inch) beyond the
repair site.
4.
Properties
Mix ratio
Working life
Drying time
Touch
Hard
Over coating
Min
Max
Application temp Min
Max
Handling Precautions
6.
Data Sheets
Material Safety and data sheets for all sealants,
primers and cleaners used to build Permastore
structures are generally provided with the project
documentation but are also available on request.
1:1 (by volume)

45 mins (at 18C)
6 hours
16 hours
16 hours
3 days
2C
30C
Whilst every care has been taken to ensure accuracy throughout this guide Permastore shall have no
liability for any loss or damage, (direct or indirect or consequential) arising out of or in connection
with this guide.
This guide is subject to supplementation or change at any time without notice at Permastore's sole
discretion.
Copyright 2009 Permastore Limited
Doc Ref: P132 Rev 9
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Page 97 of 97
APPENDIX A
Doc Ref: P132 Rev 9
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Page A1
APPENDIX A
12
10
13
11
Doc Ref: P132 Rev 9
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Page A2
APPENDIX A
14
17
15
18
16
Doc Ref: P132 Rev 9
1/5/10
Page A3
APPENDIX A
19
20
21
Doc Ref: P132 Rev 9
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Page A4

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