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Faulty Foundation Cause Faulty Tanks

 A.P.I. 650 and 653 only give general guide lines to
the type of foundation

Number of different types, evaluated on the basis for:

Risk

Cost

Constructability

Schedule
What to look for around tank to show Faulty
Foundation

Grass, moss growing out from under the tank

Trees growing from under the tank
Tank floor laid on river stone
Tank shell has edge settlement
Tank is below ground
Water lying around ring wall foundation
Ground outside foundation cracked
Water lying around tank
Timber railway ties laid under shell holding moisture
Foundation around tank is uneven
Concrete foundation has large cracks
Tank floor annular plate is starting to delaminate
Tank shell is flattening out at the top of the tank
Floating roof jams on the way up
Dike wall out of level
Tank is not level
Tank floor annular is hidden
Insulation holding moisture
Tar laid on top of annular hiding corrosion
Bottom shell course bulges out
Foundation Failure Causing Underside
Corrosion

Concrete ring wall slopes under tank

Poorly constructed or inadequate foundation material
Moisture held in the foundations
Welder sweepings under last floor sheet
Welding of the tank floor not to any code
Steel or wood leveling or layout pins
 Concrete Ring Walls and Grout

If the steel tank floor is in contact with concrete,

the moisture in the concrete and the galvanic
action between the dissimilar metals will, over a
period of time, cause the steel to corrode at an
accelerated rate.
Double Bottom Method
Developed in the 1980s as the only viable
secondary containment method, has failed
in a number of cases
With the old steel floor and a new steel floor
spaced apart with sand or concrete, the oxygen
and moisture makes a perfect battery cell and the
new floor becomes the sacrificial anode.
The new steel floor corrodes out at a rate 4 times
faster than the old floor.
C.P.must be designed and installed by experienced
contractors or it may result in increasing the rate of
corrosion of the tank floor.

Any change in the amount of moisture in the

foundation material will cause the resistivity of
the material to change and this may result in the
C.P. breaking down.
In some cases, where oil impregnated fiber board or
oil sand has been used, nature has done its work
and eaten the oil out of the sand. This can reduce the
resistance of the sand and this condition has proven
to accelerate corrosion.
NDT inspection has limitations and flaws and
cannot inspect 100% of the tank floor. It cannot
inspect the critical zone around the shell to
annular weld, lap joints, under the roof
columns, around tank sumps. Sometimes
packed rust shows up as good metal.
We have identified that many of the
problems with aboveground storage tanks
start at the foundations. Tanks not properly
founded are bound to fail.
Tank Foundation
When built on good foundations tanks have
lasted 50 and more years
 EEMUA Publication No. 159
2.2.2 Problems Caused by Soil Settlement

Even soil settlements are generally not dangerous

because they occur gradually and increase
uniformly. When they become excessive however,
some remedial action may be necessary. The extent
of settlement should therefore be checked, to avoid
problems during operation of the tank.

Pipe connection. Excessive settlement may cause

problems for the pipe connections at the tank shell.
Alternatively the pipe support may settle faster than
the tank on its foundation. Any difference in the level
may seriously overstress the pipe connection.
 EEMUA Publication No. 159

2.2.3 Additional Problems caused by Uneven Soil

Settlements
Uneven soil settlement under the shell of the tank places
the bottom periphery at greater risk than even soil
settlement. The weak flat bottom plates will follow the
uneven pattern of the soil settlement. The tank will try to
form a bridge over the area where local increased
settlement occurs. The bottom plates at that location may
not be properly supported by the tank foundations, but
may be suspended from the shell.
This is an unfavourable condition for the shell to bottom
connection and ultimately a rupture at the inner fillet
weld may occur.
Tank Settlement into the Foundation EEMUA 159

Tank
Shell
Water and Debris
Collected
Tank Bottom

Location of Possible
Shape after Corrosion
Repair
Difference in Settlement between Center and
Periphery EEMUA 159

Tank Shell

Tank Bottom

Shell settlement

Settlement at center 30% greater than at Shell

 Local uneven Settlement under the Tank EEMUA
Shell 159

Tank
Shell

Possible
Fracture Tank Bottom

Local uneven settlement under the tank should always be

treated seriously
 EEMUA Publication No. 159

a) Edge settlement

- Edge settlement may occur when the shell

penetrates into the foundation due to poor
compaction of the tank pad under the tank shell

- Edge settlement may be caused when the tank pad

shoulder is damaged or eroded by rain and wind

- Edge settlement may be caused by a tank pad shoulder

with insufficient width or poor quality construction.
 EEMUA Publication No. 159

2.2.5 Leakage
If external inspection reveals leakage from the tank
bottom, it is an indication that product is penetrating
into the foundation. This may cause a serious
condition for the safety of the tank and at the same
time cause soil pollution.

Leakage close to the periphery of the shell should be

considered as a major problem requiring urgent
attention. It should therefore be remedied
immediately as the leak may cause a local wash out of
the tank foundation under the shell
 EEMUA Publication No. 159
2.2.5 Leakage
Wash out will cause loss of support for the bottom plates
and may result in a rupture at the inner fillet weld of the
bottom-to-shell connection or the bottom lapwelds. This
would cause a sudden complete discharge of the tank
contents.

As it is impossible to predict the probability of a washout

occurring, corrective action should always be taken as
soon as possible

The possibility of a rupture increases when the tank is

filled to a high level
 EEMUA Publication No. 159

2.2.7 Relevelling of Tanks and Foundations

When settlements have reached their maximum limits,
relevelling of the foundations and the tank will be
necessary.

The tank is jacked up to a level 8 feet (2.4 meters)

above the foundation to provide sufficient space under
the tank for the repair of the tank foundations

Jacking of tanks has been successfully carried out for

tanks up to 300 foot (90 meters) diameter. The jacking
of large tanks requires a contractor with specialised
experience
 EEMUA Publication No. 159

2.3 Corrosion of Tanks

General underside corrosion should be slight where
there is a well prepared and maintained foundation.

The major causes of underside corrosion are:

- Poor drainage around tank

- Mill scale, which when present on the underside of the

tank bottom, causes preferential attack

- Water collecting around the tank and migrating under

the tank
 EEMUA Publication No. 159

2.3 Corrosion of Tanks

- Significant tank settlement that lowers the tank below
a good drainage level. This may lead to corrosion
of the annular plate around the tank perimeter.

- High natural water or underground springs

- Coral or beach sand with high chlorides used for the
foundation.
- Acidic coal based cinders or slags being included in the
foundation.
- Sharp or large stones being included in the foundation.
This may give rise to deep pitting by oxygen
concentration cell corrosion.
 EEMUA Publication No. 159

2.3 Corrosion of Tanks

- Poor quality of bitumen sand mix. B.S. 2654

- Cathode protection may have been installed after the

tank has been commissioned. In this case it
makes it difficult to ensure that sufficient
protective current reaches all areas of the bottom.

- In tanks storing heated products, there are large

differences in the tank to soil potential across the
bottom. This can cause deep random pitting.
Potentials become more anodic from the center of
the tank outwards.
 EEMUA Publication No. 159
2.3 Corrosion of Tanks
- Hot tanks increase water permeation under bottoms and
corrosion rates increase at higher temperatures.
- Stray D.C. currents may cause extremely high local
corrosion. This occurs when an external source of
direct current such as an electric railway causes
current to flow through the ground to the tank
bottom.
- Other isolated cases have included rapid galvanic
corrosion resulting from installation of a new
bottom on top of an old bottom and higher than
average corrosion rates caused by elevated
temperature.
 Air Moisture

Steel

If all 3 elements are present then corrosion can occur

Corrosion Triangle
 Remove moisture = no corrosion

Air

Steel

If all 3 elements are present then corrosion can occur

Corrosion Triangle
Remove air = No corrosion

Moisture

Steel

If all 3 elements are present then corrosion can occur

Corrosion Triangle
 EEMUA Publication No. 159

2.4 Tank Bottoms

2.4.1 Shape of Tank Bottoms due to settlement

2.4.2 Ripples in the tank bottom

2.4.3 Bottom Settlement
a) Edge settlement

- Rain water collected in the depression around the

shell will decrease the quality of the foundation
under the shell and increase the possibility of
edge settlement.
 EEMUA Publication No. 159
b) Bulges or Depressions in Bottom Plates

- When bulges are formed and not filled with foundation

material (void) there is a risk of rippling when the
tank is filled and the product contained will press the
plate downward.
- Sometimes it is proposed that these voids are filled with
liquid concrete to give support to the bottom plates
at that location. How ever this is incorrect. Slurry
will not fill these voids but will flow to those
locations where the bottom can move easily, so that
ultimately the tank bottom will rest on a number
concrete points instead of being supported evenly
over its entire surface.
Typical Tank Settlement
Curve
Settlements cause ovality of
tank shells
The EEMUA
No. 183
Publication
 EEMUA Publication No. 183
1. -Introduction and Scope

2. -Tank Foundations: Design

3. -Tank Bottoms: Design

4. -Main Causes of Tank Bottom Leakage

5. -Inspection Records and Techniques

 EEMUA Publication No. 183

6. -Other measures for preserving the Integrity of Tank

Bottoms.

7. -Available Systems for Detecting leakage and

Minimizing Soil Pollution.

8. -Condition Monitoring and Maintenance

9. -Main Conclusions and Recommendations

 EEMUA 183
2: Tank Foundations

2.6 Sand Pad Foundation with Crushed Stone Piles

Stone piles will increase the risk of ground water
pollution from leaking tanks by providing good
leakage paths deep into the soil. Such designs are
not therefore recommended for oil/chemical
storage tanks

2.7 Provision of Oiled Sand or Permeable Bitumen Sand

layer
The provision of an oiled sand or permeable bitumen-
sand layer is considered a very important
requirement for inhibiting underside corrosion. (see
Appendix 1, Fig. 2)
3 Tank Bottoms, Designs EEMUA 183

3.2 Tank Bottoms with Annular Plates

3.3 Tank Bottoms without Annular Plates

3.4 Double Bottoms

3.4 Double Bottoms Fig.10 EEMUA 183
3.4 Double Bottoms EEMUA 183

Fig. 10 The Letter Box Method

The letter box method of installing a new bottom in a

single bottom tank has been in use for more than 35
years.

When the new primary bottom is installed, support for

the bottom has to be re-established both outside and
inside the tank shell such that the old bottom and
intermediate shell are effectively redundant.
 EEMUA 183
3.4 Double Bottoms

Although there is no requirement to provide support

for the new bottom outside the shell, (API 650) paragraph
1.4.1 requires proper support of the primary bottom
and evaluation of the design to verify that the primary
bottom and shell are not over-stressed under the
specified loading conditions including tank settlement.

Such evaluation is not required where the primary

bottom is uniformly supported on both sides of the shell
and not structurally attached to the secondary bottom
or primary bottom support.
3.4 Double Bottoms EEMUA 183

-The installation of double bottoms should be carefully

evaluated, taking into account the relatively high
cost of the design and of the rectification work
required when tanks undergo progressive
settlement.

-Also the lower or secondary bottom cannot be inspected

even when the tank is out of service and
consequently its integrity is always questionable.
 EEMUA 183
3.4 Double Tank Bottoms

Complicated to Install
Relocation of Nozzles & Manholes
Sensitive to tank Settlements
Releveling virtually impossible
Removal of contaminated material from double
bottom (following leakage) potentially hazardous
New Tank Foundation Construction with Liner
 EEMUA 183
7.2 Flexible Membrane Liners in Tank
Foundation

No alterations to tank structure

Installation in combination with (scheduled)
inspection/lifting/relevelling
Future inspection/lifting/relevelling not hampered
Removal of contaminated soil (following leakage) can be
executed in open air
 EEMUA 183
2. Foundations of Storage Tanks

5 types
- type A: Traditional Sand Pad
- type B: Sand Pad with Crushed Rock Annular Section
- type C: Concrete Ring Beam Foundation
- type D: Concrete raft
- type E: Underpiled Concrete raft
Type A: Traditional EEMUA 183

Sand Pad
Top View Sand Pad EEMUA 183

Foundation
Type B: Sand Pad with Crushed
EEMUA
183

Rock Annular Section

Type C: Concrete Ring
Beam Foundation EEMUA 183
Type D and E: Concrete EEMUA 183

Raft Foundation
Soil Improvement on un-equal level
Soil Improvement on equal level
Schematic Geometry
 Execution of Soil Improvements

To what depth: same depth every where?

Extend of excavation: D + 2S + 2T + 4d (+Dd)
At un-equal soil excavation depths the excavation does
not have a circular shape
Excavation shall not exceed ground water level (No soil
improvements possible)
High quality of used materials is required
 Effect of Shoulder Width
EEMUA 183

S<1.0 m S>1.5 m
 Foundation Conclusions: EEMUA 183

Width (S) of Tank Pad Shoulder:

- 1.0 m (3FT) for tanks < 15 m (45ft) diameter
- 1.5 m (5FT) for tanks > 15 m (45ft) diameter
High Pad down-grades the Stability
- Preferable Height above Grade: 600 mm (24
inches)
- Crushed Rock Annular Section increases
Stability
Location of Leak Detection Membrane is Crucial
 EEMUA 183

9. Main Conclusions and Recommendations

-Codes and standards covering the design and construction

of storage tanks are based on over 100 years of
experience. There is no need to question the integrity
of the tank structure as a as a primary container,
provided it is properly designed and built to
recognised standards.
-Effective prevention of ground and ground water pollution
from storage tanks depends on the design and
construction of a good foundation, a properly
construction tank bottom and regular, effective
inspection.
 EEMUA 183

9. Main Conclusions and Recommendations

-Tank foundations should have a minimum height above

grade as recommended in 4.2 (24 inches 600mm)

-A course crushed rock tank pad shoulder (annular ring)

under the tank shell is preferred to a sand pad. Fig.
3 (see 2.3)

-Tank bottom annular plates should be 3/8 in (8 mm)

minimum thickness and butt welded with backing
strips (see 3.2)
 EEMUA 183

9. Main Conclusions and Recommendations

-A concrete raft structure with or without piling, though

more costly to build than other foundation types,
may be justified on the basis of long-term
maintenance costs (see 2.5)

-For storage of hot products, tank bottoms should have

cone up configuration. However for small tanks a
cone down floor on a concrete raft might be
acceptable (see 4.2)
 Tank
Foundation Ground level

Compacted Ground

Tank Foundation Settlement

Using the tank to preload the new foundation
API APPENDIX B
RECOMMENDATIONS FOR DESIGN AND
CONSTRUCTION OF FOUNDATIONS FOR
ABOVEGROUND OIL STORAGE TANKS
Questions?