THE WORLD LOOKS UP TO COMPOSITE ELEVATED TANK

Transcription

1 THE WORLD LOOKS UP TO COMPOSITE ELEVATED TANK

2 or our breadth of capability. Of all the storage tank manufacturers doing business today, no other offers Caldwell s range of capability. We are the only manufacturer that designs, builds and services all styles of elevated tanks, including composite elevated, pedesphere, fluted column, traditional multi-column and ground level tanks. For each style of tank, we offer complete, turnkey capability from initial consultation to ongoing maintenance. No matter what your need whether you are looking for elevated or ground level storage, Caldwell has a solution that is both expertly engineered and aesthetically pleasing. Add it all together and it is easy to see why when it comes to water storage, municipalities throughout North America rely on Caldwell.

3 The Composite Elevated Tank With over 120 years of experience to draw upon, Caldwell readily adopted the composite elevated tank design. After making our own set of engineering improvements, we began manufacturing the highest quality composite elevated tanks on the market in Caldwell constructs the steel tank in a skeletal framework system at the base of the concrete shaft where the container is welded together and the exterior steel is painted to project specifications. Our system provides a safer working environment by minimizing the number of labor hours required to work at high elevations. Once the exterior coating is complete, the tank is jacked into place and locked to the concrete support pedestal. The tank bottom and roof is then welded into place and the interior coating system is applied. The composite elevated tank s innovative design leads to a reduction in maintenance by utilizing reinforced concrete for the support pedestal and welded steel for the storage container. Caldwell has the capability to design and construct composite elevated tanks of any capacity and in a variety of configurations. The support pedestal can be built to include office space, pumps, valves and electrical systems or store equipment.

4 Better Engineering Makes Better Tanks Caldwell has perfected the composite elevated tank through engineering and experience. Today, there is no more technically advanced, precision engineered and expertly constructed composite elevated tank on the market. Our proprietary form system, specifically designed for the construction of composite elevated tanks, produces a finished product that is demonstrable superior to competing products. Our form panels are not made from wood, but from steel plates formed to the specified radius of the shaft. This steel form system yields a radius in full accordance with the tolerances required in the ACI 371R Guide for the Analysis, Design and Construction of Elevated Concrete and Composite Steel-Concrete Water Storage Tanks and meets all ACI construction standards and practices. Our composite elevated tanks also are in full accordance with the tolerances required in the AWWA D107-10, Standard for Composite Elevated Tanks for Water Storage. We own and maintain this form system, and unlike some competitors, we never subcontract the construction work. All of our shaft construction teams consist of skilled craftsmen with years of experience in construction, safety and quality control. Let us show you what makes our composite elevated tanks different from all the others.

5 Rigid Steel Forms Caldwell s method for constructing the concrete support pedestal is a jump form system that utilizes a series of three rings of steel forms. The rigid steel form panel is four feet in height with a locking system that secures itself to the previous ring. Successive lifts are made in which each ring of forms is jumped from the lowest position to the highest. This construction allows each ring to remain in place a minimum of 30 hours after the completion of the concrete pour to allow for superior curing. Each rigid steel form panel is designed to the specific radius of the shaft to eliminate scalloping and is constructed to withstand material, environmental and construction loads without movement or deflection. Unlike inferior materials such as plywood forms Caldwell s steel forms eliminate bulging. They also eliminate the misalignment, grout leakage and inaccurate leveling that can occur as plywood form panels wear down with use. Caldwell s system stays in place a minimum of 30 hours, where competing systems remain in place less than 24 hours. Precisely-engineered panels eliminate scalloping Rigid panels prevent form bulging Eliminates need for continuous form repair Eliminates reliance upon caulk to prevent grout leakage

6 Four Myths of Four-Foot Forms No Through-Wall Ties Required One of the major problems with standard form panels made of plywood or other flexible materials is that they must be tied through the concrete wall in order to support material loads and minimize deflection during concrete placement. These numerous form tie holes must later be patched with grout and/or plastic plugs. Caldwell s rigid steel form system eliminates the need for through-wall bolts or form ties. The four-foot panels develop significantly smaller concrete plastic head than taller form panels. Also, unlike plywood forms, Caldwell s form system securely seats and locks to the lower form in the system, securing them in place, preventing grout from leaking. Positive locking system secures panels in place Panel security does not rely on independent through-wall ties No unsightly grout patching of throughwall bolt holes or plastic plugs Myth #1 The steel plates used for four-foot forms are not heavy-duty. The Truth The Caldwell form system utilizes steel plates and structural steel to provide greater rigidity than plywood forms. Additionally, the four-foot form system eliminates both bulging, associated with imbalanced loads of wet concrete, and unsightly through-wall ties required for flimsy, imprecise form materials. Steel forms provide longer life and greater precision over time when compared to plywood forms. Myth #2 Four-foot forms create pour lines. The Truth Caldwell s form system and proprietary pour method is designed to allow quick concrete placement, eliminating the need for a segmented pour and minimizing pour lines associated with slow pour rates. Our system allows easy access to complete concrete consolidation, further minimizing unsightly shading. Myth #3 Four-foot forms cannot be sealed for grout leakage. The Truth Caldwell s steel four-foot forms are locked together using flange-to-flange connections. This eliminates grout leakage and provides a positive locking system and a more precise form alignment. Myth #4 Steel plates result in inconsistent rustication patterns. The Truth Caldwell s steel forms are actually more consistent than competitive plywood forms. Our steel forms use a positive locking system of flange-to-flange connections to ensure precise rustication patterns, time after time. The Caldwell rustication pattern also hides vertical and horizontal form joints.

7 Positive Controls for Roundness and Plumbness Caldwell s form panels provide a precise four-foot lift each time they are moved. This positive control in the form height eliminate field fitting to overlapping forms and ensures consistency. Form fit-up tolerance exceeds ACI and AWWA D107 Standards Precise four-foot lift for each move of form panels Laser measurements for plumb at each four-foot lift During construction, the inside form panels are secured to one another with the same positive seating and locking system used for the outside forms. Attached to these interior panels is a work deck that moves with each jump of the forms and allows for a safe work platform. Radial arms attached to the deck s center hub lock onto the inside form panels, maintaining a fixed dimension for the shaft. Measurements for the plumbness are taken at eight radial control points with a self-leveling Spectra Precision Laser Level. The concrete support shaft is measured after each four-foot form is jumped into place.

8 Aligned Rustication Patterns Caldwell s proprietary form panel technology not only yields a more uniform tank shaft, it produces one that is more visually appealing. Our form panels employ a unique design that hides both vertical and horizontal form joints. Both patterns are permanently attached to the form panels ensuring accurate alignment of the repeating pattern. The vertical rustication pattern on each form panel is designed to accomplish two things: to increase the rigidity of the steel form panel and to conceal the vertical form joint at the far edge of the connecting panels. The Caldwell jump form system also hides the horizontal form joint, by allowing the form rings to attach to one another instead of the previous pour. The locking system also eliminates the possibility of any form panel misalignments. Rustication pattern hides vertical and horizontal form joints Permanently secured patterns ensure consistent rustication alignment Horizontal rustication pattern hides construction joint of previous lift

9 No Grout Leakage Caldwell s rigid steel form panels have a fixed flangeto-flange connection. The positive seating and locking system on each panel provides a grout-tight seam without caulk between each series of forms. Other tank manufacturers use overlapping forms that connect directly to the previous concrete pour, which does not provide a positive seating of the form, resulting in the reliance on pliable caulk to provide a seal. Their method allows for gaps to occur between the form and the previous pour, creating a void that leads to grout leakage and staining of the concrete. Flange-to-flange connection eliminates grout leakage Flange-to-flange connection provides positive locking system Eliminates alignment errors caused by overlapping form systems

10 Reduced Concrete Shading Caldwell s form system is designed for proprietary mixing and quick concrete placement to minimize pour lines and concrete shading. When concrete is delivered to the site typically two truckloads per ring section they are blended as the concrete is pumped, thus minimizing any shading inconsistencies that can arise from variations in the concrete s composition. Proprietary mixing system Quick placement of concrete No drop chutes or tremies required Easy access for consistent concrete consolidation No vertical construction joints from temporary bulkheads Because Caldwell s form system does not require a segmented pouring procedure, nor the use of temporary bulkheads, all concrete pours stay consistent and even in appearance.

11 Standard Accessories (American Water Works Association) Frost-proof pressure/vacuum relief vent Roof hatch with hinged cover and hasp Bolted roof hatch for attachment of exhaust fan Access tube roof hatch Access tank floor manhole Removable access hatch at top of supporting pedestal Purchaser-specified stainless steel inlet/outlet piping with expansion joint Pedestal supported stainless steel overflow pipe to grade level Supporting shaft and access tube ladders with OSHA-compliant safety climb devices. All ladders, walkways, handrails and attachments inside the pedestal are galvanized Rest seats at desired intervals Upper pedestal walkway with OSHA-compliant handrails Personnel door in base of supporting pedestal Overhead door in base of supporting pedestal

12 Commonly Utilized Accessories Larger diameter manholes and hatches Overhead rolling door Roof handrail Cellular antenna supports Intermediate rest platforms with OSHA-compliant handrails Insulated tank piping Piping in base of shaft, bypass lines, altitude valve, service pumps, etc. Additional free-span floors Masonry block building in base of pedestal Overflow flap valve High water elevation/pressure gauge Available space for multiple floors and multi-use, such as office space or storage

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14 4000 Tower Road, Louisville, Kentucky PH: (502) FAX: (502) Southern Manufacturing Facility 57 East Broad Street, Newnan, Georgia PH: (770) FAX: (770)