300 Foundation Design and Construction PDF

300 Foundation Design and
Construction
Abstract
This section of the manual discusses the design and construction of atmospheric
storage tank foundations. Company and industry specifications are discussed and as
well as the data required to determine the most appropriate foundation for a tank. It
addresses tank foundations preferred for the different types of soil conditions. This
section also includes settlement and releveling and provides procedures to address
these issues.
Due to the critical nature of tank foundations, a civil engineer should have responsi-
bility for the design work.
Contents Page
310 Soils Considerations 300-3

311 Designs to Compensate for Settlement
320 Foundation Design 300-4
321 Environmental Requirements
322 Design Loads and Forces
323 Foundation Types
324 Bottom Support Pad
325 Foundations for Hot Tanks
326 Foundations for Small Tanks
327 Berms and Gutters
328 Catch Basins and Sumps
330 Grounding Considerations 300-45
331 Grounding for Aboveground Metallic Tanks
340 Foundation Construction 300-46
341 Concrete Work
Chevron Corporation 300-1 July 2000

300 Foundation Design and Construction Tank Manual
342 Installing the Secondary Containment and Leak Detection System

343 Bottom-to-Foundation Seal
350 Tank Settlement 300-49
351 Spotting Settlement Problems
352 Kinds of Settling
353 Settlement Criteria
354 Designing for Settlement
355 Releveling Tanks
360 References 300-68
July 2000 300-2 Chevron Corporation

Tank Manual 300 Foundation Design and Construction
310 Soils Considerations
311 Designs to Compensate for Settlement

Several differential settlement-related tank problems can be minimized at the design
stage. Two design solutions are discussed, one for a cone up bottom and the other
for a cone down bottom.
Pascagoula DesignCone Up Bottom

Figure 300-1 shows a tank bottom configuration designed to compensate for differ-
ential settlement. This design has been successfully used at the Pascagoula Refinery.
Fig. 300-1 Cone Up Tank Bottom ConfigurationPascagoula Refinery
Tank bottom plates are placed in a cone up configuration to compensate for

differential settlement. The tank bottom layout shown in Figure 300-1 was specific
for site conditions at the Pascagoula Refinery. This curve is the maximum
recommended; steeper slopes may cause the bottom plate to crease.
This design can be applied to other sites where large differential settlement is
anticipated. The parabolic portion of the tank bottom layout is defined by
considering soil conditions, tank diameter, and tank height. Consult with a soils
specialist or the CRTC Fitness for Service, Civil/Structural Team for assistance.
Cone Down BottomCenter Sump Design

Another solution is to construct a bottom with a minimum downward slope (1 inch
in 10 feet) using a center sump and siphon water draw. While the permissible
differential settlement for this configuration is less than that for a cone up bottom,
the disadvantages of the cone up bottom are avoided. A cone down bottom assures
good drainage to the center sump even if the tank settles.

320 Foundation Design

Selecting the appropriate tank foundation depends to a great degree on the type of
soil under the specific tank site as discussed earlier and also on the location of the
tank field.
For example, special precautions are required for tank foundations in high
earthquake zones or frost regions. The dimensions of tanks in high earthquake zones
must be proportioned to resist overturning forces or the tanks must be anchored.
In frost regions, extend tank foundations one foot below the frostline to prevent
frost heave. A properly designed tank foundation includes leak detection methods
and cathodic protection if required.
321 Environmental Requirements

Chevron recommends that the following be installed, whenever possible, on tanks
handling stock that could contaminate groundwater if spilled:
secondary containment;
leak detection systems; and
cathodic protection.
These systems can be installed on new tanks or on existing tanks during bottom
replacement. Designs for this type of foundation are discussed in Sections 540, 260,
Membrane Design and Selection and 650, Cathodic Protection.
When secondary containment and leak detection is not practical (tanks with large
settlement, for example), consider external cathodic protection. Cathodic protection
is discussed in Section 650.
Not all of the foundations discussed in Section 323 can accommodate these systems.
322 Design Loads and Forces

Tank foundations should be designed for the following loads and forces when they
exist.
Dead Load
Dead load consists of the weight of the metal (shell, roof, bottom plates, access
ladders, platforms, nozzles, manways, roof support columns, etc.).
Design plate thickness to include corrosion allowances.
Product Load
Product load refers to the weight of the stored product.
Use maximum product depth and specific gravity when calculating the weight.

Vapor Pressure
Internal pressure on the roof and surface area of the product is identical; however,
the bottom plate (usually -inch thick, lap fillet welded) is not structurally capable
of transferring the vapor pressure to the shell to counterbalance the upward pressure
from the roof.
Foundations for tanks subjected to internal pressures must be designed to resist
the uplift forces.
This topic is discussed in more detail in Section 512, Internal Pressure Tanks.
Snow Load
For tanks in Company facilities located in snow regions:
include the weight of the snow in the design of the foundation
calculate snow load in accordance with ANSI/ASCE 7/98, Building Code
Requirements for Minimum Design Loads in Buildings and Other Structures.
Temperature
Tanks that store hot products are subjected to variations in temperature which can
lead to deformations or movements. In the tank foundation, incorporate details that:
allow the tank to move
protect the foundation concrete
Wind
Tank foundations must be designed resist wind pressures.
This is particularly important for tanks that may sit empty or only partly filled.
Calculate wind loads on tank foundations in accordance with Section 530 of
this manual.
Earthquake
Earthquake-induced lateral forces can cause a tank to tip, overturn, or slide.
For additional information regarding seismic design of tank foundations, see
Section 530 of this manual.
Tipping
If the tank does tip on edge, the flexible tank bottom diagonally opposite can
lift only a small amount of contents to resist the seismic overturning force. The
force of tipping subjects the foundation area under the shell to large vertical
compressive forces.
Overturning
The weight of the tank plus its contents and the tanks H/D (height-to-diameter)
ratio affect the tanks ability to resist overturning.

Small diameter tanks are more susceptible to overturning than large

diameter tanks, because they usually have greater H/D ratios.
To verify tank stability, add the foundation weight to the tanks shell
weight, Wt (see API 650 Appendix E) and analyze the tank as unanchored.
Unless additional information is available, assume the tank is flexible and
ringwall designed for the full uplift forces.
Adjusting the H/D ratio is the preferred method to prevent tipping. (You
can also anchor the tanks, but this method is not recommended in larger
tanks.)
a. For flat-bottomed tanks, adjust the H/D ratio rather than add
anchors because ringwall or concrete slabs may become excessive
or require piles to resist the uplift forces. (See Section 140 for
recommended H/D ratios.)
b. In some cases, the ringwall weight may be enough to make the
tank stable without piles.
Sliding
In seismically active areas, the soil stability must be investigated.
Analyze the tank site to determine the potential for liquefaction or sliding
during an earthquake (this information should be included in the soils
investigation report).
Calculate earthquake loads in accordance with API Standard 650,
Appendix E.
323 Foundation Types

How to Choose a Foundation
Choose an appropriate tank foundation design based on the following:
tank size,
soil type; and
environmental requirements to detect and protect groundwater from leaks.
Tank Size
Large Tanks (50 feet in diameter or greater)
use concrete ringwall (preferred) or crushed stone ringwall.
Small Tanks (20 feet in diameter or less)
use concrete slab foundation (preferred) or compacted granular fill
foundation.
Medium Tanks (20 to 50 feet in diameter) can be classified as either large or
small at the discretion of the foundation designer and tank design engineer, for
the purpose of choosing the type of foundations only.

Soil Type
In some instances, large fixed roof tanks can be supported directly on properly
prepared good native material. Choose this method only if recommended by the
soils consultant.
Pile supported concrete slab foundations are used for tanks on poor soils, regardless
of the tank size.
Environmental Requirements
These are determined by local environmental standards and requirements. Consult
with local environmental specialists for recommendations and requirements.
Foundation Types
Figure 300-2 summarizes foundation types, lists the advantages and disadvantages
of each type, and makes specific recommendations.

Fig. 300-2 Tank Foundation Summary (1 of 4)
July 2000
300 Foundation Design and Construction

Foundation Type Advantages Disadvantages Recommendations Reference Documentation
Concrete Ringwall 1. Provides level surface 1. Can be expensive, Preferred foundation type Standard Form TAM-EF-364
circular wall for shell construction. depending on location. for tanks larger than 20 ft. in outlines concrete ringwall
centered continu- 2. Minimizes edge 2. May not be suitable for diameter. Can also be used design and construction
ously under shell settlement. tanks on poor soils. for small diameter tanks details.
circumference. Check with foundation when anchorage is not API Standard 650, Appendix
3. Easy leveling for tank required.
grade. specialist. B, lists several other advan-
3. Ringwall must be Use on good soils or prop- tages of foundations with
4. Minimizes moisture erly prepared intermediate ringwalls over foundations
under tank. reinforced.
soils. without ringwalls.
5. Retains fill under tank 4. Anchoring of tanks
against earthquake Concrete ringwall is the ACI 318, Building Code
and prevents loss due preferred foundation for all Requirements for Rein-
to erosion. overturning not
practical. Requires large tanks, for tanks where forced Concrete
6. Distributes concen- special design. the surface soil is non-
trated shell load well. cohesive, such as loose
The only disadvantage of sand, for tanks where
7. Can use cathodic concrete ringwalls is that
300-8
protection. significant settlement is

they are more expensive anticipated, and on all
8. Provides greatest than earth foundations floating roof tanks over
assurance of meeting without a ringwall. 30 feet diameter to protect
elevation tolerances against differential settle-
around tank circumfer- ment-caused problems with
ence. annular space and tank seal
9. Better able to transfer
shell loads to the
supporting soil.
10. Minimizes edge settle-
ments and conse-
quently shell
Chevron Corporation
distortionsvery
important problems to
avoid for trouble-free
Tank Manual
operation of tanks with
floating roofs.
Chevron Corporation
Tank Manual
Crushed Stone 1. Less expensive than 1. Tank cannot be Use where concrete for API Standard 650,
Ringwall concrete ringwall. anchored against earth- ringwall not readily Appendix B
2. Good concentrated quake overturning. available or high cost of
construction. Use on good
Tank Manual Section
shell load distribution to 2. Greater care required 526, 527
weaker soils below. for preparation of tank soils or properly prepared
grade. intermediate soils.
3. Construction material
usually readily 3. Foundation material This type of foundation,
available. subject to washout. though not as desirable as a
concrete ringwall founda-
4. Can make use of 4. Not suitable for poor tion, is a good alternative,
cathodic protection. soils. especially in areas with
5. May cause increased good soil and where
undertank pitting at concrete is either not
points where tank readily available or is costly.
bottom contacts stones.
300-9
A drawback with crushed

stone is that water and
corrosive salts can collect
between the stones and
cause increased pitting
rates. A concrete ringwall
will generally cause less

bottomside corrosion where
it contacts the tank bottom.
July 2000
July 2000

Concrete Slab 1. Provides level surface 1. Relatively expensive, Use for small tanks where ACI 318, Building Code
for shell and bottom especially for large leak detection and contain- Requirements for Rein-
construction. tanks. ment are required. forced Concrete.
2. Minimizes differential 2. Shifting and settling on Not recommended for tanks Standard Drawing GF-S1121
settlements. poor soils may cause larger than 20 ft. in diam-
3. Good concentrated slab to crack. eter because of cost.
shell and uniform load 3. Cannot use cathodic Use on good soils or prop-
distribution. protection. erly prepared intermediate
4. Does not require The disadvantages of soils.
separate bottom concrete slab foundations
support pad. are their higher cost and
5. Can be designed to the fact that they do not
allow for tank permit the installation of
anchorage against cathodic protection.
earthquake overturning.
300-10
6. Leak detection and

containment can be
incorporated.
7. Low corrosion rate.
The concrete slab has all
the advantages of the ring-
wall, plus it can easily
incorporate leak detection
systems as shown in Stan-
dard Drawing GF-S1121.
Chevron Corporation
Tank Manual
Chevron Corporation
Tank Manual
Compacted 1. Relatively inexpensive. 1. Limited to small tanks Use on good soils only.
Granular Fill 2. Easy to construct. on good soils.
3. Construction material 2. Tank cannot be

readily available. anchored against earth-
quake overturning.
3. Foundation material
subject to washout.
Pile Foundation 1. Minimizes total and 1. Most expensive Use for all tank foundations Standard Form TAM-EF-421
differential settlement. foundation type. on poor soils where no Standard Drawing GF-S1121
2. No separate bottom pad 2. More complex design other foundation type is
required. than other types. possible.
3. Allows for tank 3. Good soils information

anchorage against essential.
earthquake overturning. 4. Cathodic protection
300-11
4. Leak detection and more difficult to install.

containment can be
incorporated.

July 2000
Concrete Ringwall Design

To minimize differential settlement, the concrete ringwall should be proportioned so
that soil pressure under the ringwall equals the soil pressure under the confined
earth at the same depth as the bottom of the ringwall.
Ringwalls need to be a minimum of 12 inches wide and 35 inches deep, with at
least 12 inches above grade and 24 inches below grade.
A greater depth may be required in loose sand.
The minimum concrete strength should be 3000 psi at 28 days.
Design concrete and reinforcement in accordance with ACI 318, Building
Code Requirements for Reinforced Concrete and API Standard 650,
Appendix B.
Reinforce the concrete ringwall to reduce shrinkage cracks and to resist hoop
tension.
Hoop tension is caused by the lateral earth pressure inside the ringwall due to
the product surcharge and applicable tank dead load, such as from the tank
bottom plate and roof columns.
The lateral earth pressure shall be assumed to be at least 50 percent of the
vertical pressure due to fluid and soil height, unless substantiated by proper
geotechnical analysis. If a granular backfill is used, a lateral earth pressure
coefficient of 30 percent may be used.
Ringwalls need not be designed to resist active soil pressure inside the ringwall.
Neglect passive pressure on the outside of the ringwall.
Mobilization of active and passive earth pressures implies substantial
movements which are not likely to occur in a circular concrete ringwall.
The top of the concrete ringwall should be a minimum of three inches above
the adjacent grade if paved and six inches if unpaved, after predicted
settlement.
Place inch thick maximum, asphalt impregnated board, such as ASTM
D1751, on top of the wall directly underneath the shell annular plate, except for
hot tanks.
An example for designing a ringwall foundation is given at the end of this section.
Backfill. The space within the ringwall is backfilled with compacted granular fill
capable of supporting the tank dead load and the product surcharge load.
Backfill should be select material of such size and gradation as to be easily
compacted and have good drainage characteristics.
California standard Class 2 roadway aggregate base, inch maximum size, is
suitable for backfill.
Material meeting the requirements for roadway base in other localities is also
acceptable backfill.

Crushed Stone Ringwall Design

API Standard 650, Appendix B, suggests a general type of crushed stone ringwall
foundation. More specifically, the crushed stone ringwall should consist of:
Crushed gravel or crushed stone one-half to one inch in diameter.
Make the crushed stone ringwall base wide enough to distribute the shell loads
to the underlying soil without exceeding the allowable bearing capacity.
Base the ringwall base width and depth below the bottom of the tank annular
plate on the recommendation of the soils consultant.
The minimum depth is two feet.
Design all other ringwall dimensions as shown in API Standard 650, Appendix B,
except that the berm outside the tank should be as discussed in Sections 326 and
327.
Backfill. The space within the crushed rock ringwall is backfilled with compacted
granular fill of the same quality as that for concrete ringwall foundations.
Concrete Slab Foundation Design

Concrete slab tank foundations can be utilized to support small unanchored or
anchored tanks. The concrete slab provides an outstanding level, uniform tank
support surface and makes it possible to anchor the tank using conventional anchor
bolts.
The slab must be thick enough to develop the anchor bolt forces and rigid
enough to transfer the tank loads to the soil without cracking.
Design structural concrete according to ACI 318, Building Code
Requirements for Reinforced Concrete.
Reinforce the concrete slab to reduce shrinkage and to resist shear and bending
moments produced by soil bearing pressures.
Reinforcement can consist of deformed steel bars or deformed welded wire
fabric.
Make the concrete slab heavy enough to resist overturning forces with a factor
of safety of 1.5.
For small production tanks, precast concrete slabs transported to site by truck may
offer a quick, simple and cheap foundation.
Compacted Granular Fill Foundations

Unanchored small tanks can be supported on compacted granular fill placed directly
over native material. The granular fill should be a minimum of one foot deep.
Erosion. Protection against erosion can be accomplished in one of two ways:
Build a three-foot wide shoulder and berm
Place a steel band around the periphery of the tank.

The steel band confines the fill and prevents sloughing of loose, non-cohesive
surface soil.
Construction details for a tank foundation with a steel band are shown in
Figure 300-3.
Fig. 300-3 Granular Fill Foundation with Steel Plate Band
Drainage. If the native soil does not drain, the fill could stay full of water and cause
increased corrosion. It is important that:
the native soil be sloped for drainage; or
cathodic protection be used to protect the bottom.
Pile Supported Concrete Foundations

If tank loads and soil conditions do not economically permit any of the previously
discussed foundation types to be used, then a pile supported foundation may be the
only practical alternative.
Standard Form TAM-EF-421 (Pile Supported Concrete Foundation) shows typical
details for a pile supported mat foundation. Standard Drawing GF-S1121
incorporates the groundwater protection details into the pile supported tank
foundation design.
The procedure for the design of pile supported foundations is:
1. It is very important to involve a civil engineer in the design of this type of
foundation.
2. Make a soils investigation to determine groundwater levels, allowable pile
loads, and required pile lengths.
3. Calculate the loads and estimate the total number of piles.
4. Determine type, capacity, and length of piles. This step is normally done by the
soils consultant.
5. Establish pile spacing.

6. Design the pile cap and concrete slab.

7. Check pile uplift and lateral loads due to wind or earthquake.
Ringwall Foundation Design Example

Because of the large compressive forces in the shell, the ringwall design is critical.
The following example (Figure 300-4) and accompanying calculations based on
API 650 and ACI 318 describe the procedures to be used.
Fig. 300-4 ExampleRingwall Foundation Design (1 of 11)
P =P +P
T DL EQ
TANK
W
EQ
ANNULAR
RING TANK SHELL
H
R
TANK BOTTOM
CONCRETE PLATE
WP
RINGWALL
TOP OF
q
e
BERM P
h
ACTIVE SOIL PRESSURE

2 - 0"
(NEGLECT)
0.5 W P (MIN.)
PASSIVE SOIL SHEAR RESISTANCE (NEGLECT)
PRESSURE
(NEGLECT) q rw
b
Ref. 1) API 650 12" MIN
2) ACI 318
RINGWALL & TANK SHELL
Legend for this figure is on the next page

Figure 300-4 continues on the next page


Legend:
R = tank radius, ft.
H = tank height, ft.
b = width of ringwall, ft. (should be at least 12 in.)
h = height of ringwall, ft.
c = unit weight of concrete, pcf
e = distance of top of ringwall from top of berm, ft.
PT = total load on tank shell, lb./ft.
PDL = dead load on tank shell, lb./ft.
PEQ = earthquake load on tank shell, lb./ft.
Wp = product load on tank bottom, psf
WEQ = earthquake load on tank bottom, psf
qp = soil bearing under tank at centerline, psf
qrw = soil bearing under ringwall, psf
qDL = allowable soil bearing pressure due to tank dead load + product weight
qEQ = allowable soil bearing pressure due to tank dead load + product weight + earthquake
To = applied uniform torsional moment in the ringwall, kip-ft/ft
x = distance of centerline of tank shell to centerline of ringwall, ft.
MA, MB = internal bending moment in the ringwall, kip-ft
TA, TB = internal torsional moment in the ringwall, kip-ft
fy = yield strength of reinforcing steel, psi
fc = compressive strength of concrete, psi


1. Determine Ringwall Dimensions
Design objective: For dead load plus product weight, proportion the ringwall so that the average soil bearing
pressure under the ringwall is approximately the same as the average soil bearing pressure under the centerline
of the tank.
Given
D = 120 ft.
H = 60 ft.
Content = crude oil, s.g. = 0.93
Earthquake zone 4
e = 6 in h = 6 " + 2 - 0" = 2 - 6"
Soil data:
Allowable soil bearing pressure (from soil report):
Tank dead load (steel) + product weight

qDL = 4, 500 psf
Tank dead load + product + earthquake

q EQ = 1.33 q DL = 6, 000 psf
Projected differential settlement = negligible

Projected uniform settlement: - 2 in. - completed by the end of the hydrotest
Foundation loading (from API 650 Appendix E Evaluation or vendor data):
PDL = 1,800 lb./ft. (including contributing roof dead load)
PEQ = 14,200 lb./ft.
PT = 1800 + 14,200 = 16,000 lb./ft.
Wp = qp = 59 ft. 62.4 lb./ft.3 0.93 s.g. = 3,424 psf
WEQ = 791 psf.
The tank requires no anchorage. (Per API 650 Appendix E Evaluation.)
Case I. DL + Product
qp = Wp = 3424 psf

q DL = 4500 psf. > 3424 psf. Therefore OK

P DL
- + ( c h ) = qp
q rw = --------
b
Solving for b:
P DL
b -------------------------
qp ( ch )
1800
b ------------------------------------------
3424 ( 150 2.5 )
b 0.59 ft. < 1.0 ft. min.
Case II. DL + Product + EQ

qp = Wp + WEQ
= 3424 + 791 = 4215 psf

q EQ = 6000 psf. > 4215 psf. Therefore, OK.
P T ( W p + W EQ ) ( b 2 )
q rw = ------ + --------------------------------------------- q EQ
b b
Solving for b:
PT
b ---------------------------------------------------
1
q EQ -- ( W p + W EQ )
2
16000
b -------------------------------------------------
1
6000 -- ( 3424 + 791 )
2
b 4.1 ft. Use b = 4.0 ft. (close enough)
2. Calculate Ringwall Reinforcement
a. Material
Concrete, fc = 4000 psi
Reinforcing steel, fy = 60,000 psi (ASTM A615, Grade 60)


b. Hoop Tension
Th = 0.5 Wp D (d/2)
0.5 3424 120 2.5 2

= --------------------------------------------------------- = 257 kips
1000
where:
D = tank diameter, ft
Th = hoop tension in ringwall, lb.
c. Torsion and Bending Moment

T o = P T x + ( W P + W EQ ) --- + --
b x
4 2
Since the tank shell will be placed nomi-

nally at centerline of ringwall,
therefore, x = 0.
b
T o = --- ( W EQ + W P )
4
4 1
= -- ( 3424 + 791 ) ----------
4 1000
= 4.22 kip-ft/ft
MA = MB = To ( D 2 )
= 4.22 ( 120 2 ) = 253 kip-ft
T A = T B = 4.22 ( 120 2 ) = 253 kip-ft
Note: The procedure presented above for calculating the internal shear, bending moment and torsion is
applicable for footing on soil with negligible differential settlement. Beam-on-elastic foundation analysis or
other similar analysis should be employed if significant differential settlement is anticipated.


d. Longitudinal Reinforcement for Hoop Tension
Factored Load, Thu = 1.7 Th = 1.7 257 = 437 kips (per ACI 318)
Strength Reduction Factor, = 0.9
Thu/ = ultimate design hoop tension, kips
T hu 437
- = ------- = 485 kips
-------
0.9
AsH = Required Hoop Steel Reinforcement, in2
T hu 485 2
= -------- = ------- = 8.1 in
f y 60
e. Longitudinal Reinforcement for Flexure

Factored Load, Mu = 1.4 MA or 1.4 MB.
Mu= 1.4 253 = 354 kip-ft [per UBC for Seismic Zone 4 U = 1.4 (D + L)]
Strength Reduction Factor, = 0.9
Mu
------- = ultimate design moment, kip-ft

M 354
------u- = ------- = 393 kip-ft
0.9
2 2M u A
= A A ----------------
2
f y bd
where:
0.85fc 0.85 4000
A = ---------------- = -------------------------- = 0.057
fy 60000
d = distance from extreme compression fiber to centroid of longitudinal tension reinforcement

d 30 3 0.5 0.5 = 26
2 2 393 12 0.057
= 0.057 0.057 ----------------------------------------------------
2
0.9 60 4 12 26
200 200
= 0.0028 < min = ------- = ------------- = 0.0033 Govern
fy 60000
min per ACI 318



AsM = Required steel reinforcement for flexure, in2
= bd =
= 0.0033 (4 12) 26
= 4.12 in2
f. Reinforcement for torsion and shear

Factored torsional moment, Tu = 1.4TA (or) 1.4TB
= 1.4 253 kip-ft = 354 kip-ft
\ K
Factored shear force, Vu = 1.4 V
=0
Note: The shear force in the ringwall is
not always equal to zero. When large ;
differential settlement exist, shear force
E
in the ringwall could be significant.
x1 = 48" - 2(1.5 + .25) = 44.5"
Strength Reduction factor, = 0.85
y1 = 30" - 3 - 1.5 - 2(.25) =25
T u 354 b = 48"
T n = ----- = --------- = 416 kip-ft
0.85 h = 30"
The effect of torsion may be neglected if

A 2 cp
T u < fc -----------
P cp
A 2 cp ( 48 30 )
2
1
fc ----------- = 0.85 4000 ------------------------ ----------------------
cp
P 2 ( 48 + 30 ) 12 1000
= 59.5 kip-ft
Tu = 354 kip-ft > 59.5 kip-ft, therefore the effect of torsion must be considered.
where:
Acp = Area of concrete cross section, in2
= bxh
Pcp = Outside perimeter of concrete cross section, in
= 2 (b + h)
AL = Required longitudinal reinforcement for torsion, in2
At = Required ties reinforcement for torsion, in2

Av = Required ties reinforcement for shear, in2

Aoh = Area enclosed by the centerline of the outermost closed hoops (ties), in2
= x1y1
Ao = 0.85 Aoh
Ph = Perimeter of centerline of outermost closed hoops (ties), in
= 2 (x1 + y1)
fyv = Yield strength of tie reinforcement, psi
fyL = Yield strength of longitudinal reinforcement, psi
= 45
s = tie spacing, in
Design of Ties Reinforcement

For Torsion:
2A o A t f yv Co tan gent
T n = ----------------------------------------------------
-
s
Tn = Tu/ = 416 kip

Ao = 0.85 x 44.5 x 25 = 945.6 in2
A
Solving for -----t :
s
A Tu
-----t = ----------------------------------------------
-
s 2A o fyv Co tan gent
416 12 1000
= ------------------------------------------------------------------------------
( 2 ) ( 945.6 ) ( 60000 ) ( Cotangent45 )
= 0.044 in2/in (per one leg of ties)
For Shear:
V -----u- V c
Av Vs
------ = ------- = ----------------------- (per two legs of ties, in2/in)
s fyd fy d
V A
since no shear in footing, -----u = 0 , -----v = 0
s


Min Required Ties,
50b s
2At + A v = -----------------
fy
Av = 0
A 50 4 12
-----t 2 2
= ------------------------- = 0.02in in < 0.044in in
s min 2 60000
Govern
x1 + y1 44.5 + 25
s max = ---------------
- = -------------------- = 17.4 in
4 4
or
d 26
s max = --- = ----- = 13 in Govern
2 2
0.2
For #4 ties, At = 0.2 in2; Required s = ----------- = 4.55 in. < 13 in.
0.044
0.31
For #5 ties, At = 0.31 in2; Required s = ----------- = 7.05 in. < 13 in.
0.044
Select #5 @ 7 in. o.c. closed ties
Design of Longitudinal Reinforcement
At f yv
A L = ----- P h ------ Co tan gent
2
s f
yL
2
= ( 0.044 ) ( 2 ) ( 44.5 + 25 ) ------------- Co tan gent 45
60000
60000
2
= 6.12 in

A t f yv
( A L ) min = ( 5 f c )A cp ----- ------ P h
s f
yL
= ( 5 4000 ) ( 48 30 ) ( 0.044 ) ------------- ( 2 ) ( 44.5 + 25 )

60000
60000
= 7.59 6.16
2 2
= 1.43 in < 6.12in
Therefore, provide AL = 6.12 in2
g. Select Longitudinal Reinforcement

h 2
For Hoop Tension, A s = 8.1 in
For Torsion, AL = 6.12 in2
h 2
A s + A L = 8.1 + 6.12 = 14.22 in --- Distributed on all sides ---
Bar Size # of Bars As
#6 32 14.1 in2
#7 24 14.4 in2
#8 18 14.22 in2 SELECT 6 bars on top and bottom
3 bars on each side
For Flexure, ASM = 4.12 --- On top and bottom
Bar Size # of Bars AS
#6 10 4.40 in2
#7 7 4.20 in2
#8 6 4.74 in2 SELECT 6 bars on top and bottom
See the following figure for reinforcement detail
5
@ 7" o.c.
2
12 - #8 ON TOP AND BOTTOM

3 - #8 ON EACH SIDE
(TOTAL 30)
STAGGER SPLICES
4
Concrete Ringwall Reinforcement Detail


h. Temperature Requirement
Per API 650, Appendix B,
Ast = (0.002) (Arw)
where:
Ast = total area of temperature rebar above grade, in2
Arw = cross-sectional area of ringwall above grade, in2
Arw = b e = 4 ft. .5 ft. = 288 in2
Ast = .002 288 = 0.576 in2
From Step 2g above, and the accompanying figure, actual amount of rebar above grade
= 12 bars 0.79 in2/bar = 9.48in2.
Therefore, 30 #8 bars as shown are okay.
This is the end of Figure 300-4
324 Bottom Support Pad

Depending on the choice of corrosion protection and leak detection method, the area
within the ringwall and above the aggregate backfill can be covered with:
reinforced concrete slab
sand pad
asphaltic concrete pavement, or
penetration macadam.
Tank pad settling due to compression, particularly on asphaltic concrete or
penetration macadam pads, makes a groove at the edge of the tank shell. Water
accumulating in the groove causes the tank to corrode. To prevent corrosion, lower
the shoulder around the tank and properly drain away water from the tank.
Figure 300-5 summarizes the bottom pad types and makes specific
recommendations regarding leak detection and containment, and corrosion
protection. Further discussion on this topic can be found in Sections 250, 260, and
650.
Reinforced Concrete Slab

Make this pad:
a minimum of five inches thick
over a four-inch sand or compacted fill cushion
Refer to Standard Form TAM-EF-364 and Standard Drawing GF-S1121.

Fig. 300-5 Summary of Tank Bottom Support Pads (1 of 2)

Incorporation of
External
Bottom Support Leak Detection Cathodic Reference
Pad Type and Containment Protection Comments Documents
Reinforced Can be incorporated. Not required. Must be reinforced. EF 364
Concrete Slab It can easily accom- will not permit Use where leak detection and GFS1121
modate leak detection cathodic containment are required.
protection. Do not use where cathodic protec-
tion is required.
Outstanding support surface for the
bottom plate.
Do not use this pad where the
anticipated differential settlement is
more than one inch in ten feet.
Plain Sand Pad Can be incorporated. Easiest to Sand subject to shifting and voids
incorporate. can be created under bottom. Easy
to construct; difficult to maintain
while installing bottom.
Use where leak detection and
containment and/or cathodic
protection are required.
it can accommodate both cathodic
protection and leak detection.
Disadvantages:
The sand can shift causing voids
and low spots.
Laying of the bottom can disrupt the
contour of the sand.
While shifting sand is a concern,
however, the problems caused by
shifting sand are generally less than
those caused by a concrete pad on
shifting ground, since cracking and
break-up of the concrete is a
serious problem.
Any oil added to the sand can
represent pollution and potential
groundwater contamination.

Fig. 300-5 Summary of Tank Bottom Support Pads (2 of 2)

Incorporation of
External
Bottom Support Leak Detection Cathodic Reference
Pad Type and Containment Protection Comments Documents
Asphaltic Leak detection Difficult to Has been widely used in the past. EF-364
Concrete possible but not incorporate. Use for tanks not requiring leak Section 650
usually used. detection or long-term cathodic
protection.
We now recommend against
asphaltic concrete pavement since
it does not deter corrosion in the
long run, and limits the future instal-
lation of cathodic protection unless
the pavement is removed.
Penetration Leak detection Difficult to Use for tanks in remote sites where EF-364
Macadam possible but not incorporate. other material not readily available.
usually used. Do not use if leak detection and
containment and/or cathodic
protection are required.
Generally less costly than other
pavement types for locations
remote from a mixing plant.
It is believed to provide an
adequate water barrier for most
tank foundation conditions, but is
not likely to be as good in inhibiting
corrosion as a clean sand or
concrete pad.
Do not use where corrosion protec-
tion of tank bottom plates is required.
Granular Fill Leak detection Can be See Tank Foundation Summary
very difficult or incorporated. Figure 300-2.
impractical.
Plain Sand Pad

Make this pad:
at least four inches thick
out of clean, salt free sand (causes much less corrosion than either gravel or
crushed stone).
Some localities allow the use of oil in sand as a corrosion inhibitor. We have
found that oil does not increase corrosion resistance much, and that in some
cases has actually increased corrosion rates. Any oil added to the sand can
represent pollution and potential groundwater contamination.
Rather than using oil as a corrosion inhibitor, consider installing cathodic
protection in the sand pad.

Asphaltic Concrete Pavement

This type of pad has been used in the past to support tank bottoms.
Note Asphaltic concrete pavement is not recommended for new construction. The
pad can initially prevent water from migrating up through the foundation and
corroding the tank bottom. Experience shows, however, that water eventually
migrates up through the pavement and corrodes the tank bottom.
Design and construction details for this pad are shown on Standard Form
TAMEF364.
Note We now recommend against the use of an asphaltic concrete pavement since
it does not deter corrosion in the long run, and limits the future installation of
cathodic protection unless the pavement is removed.
For more information on Cathodic Protection, see Section 650.
Penetration Macadam Pavement

Penetration macadam is used extensively as a tank pavement. It contains successive
layers of progressively smaller angular stones. Each layer is consolidated by rolling,
after which it is sprayed with bituminous binder.
Penetration macadam is generally less costly than other pavement types for
locations remote from a mixing plant. It is believed to provide an adequate water
barrier for most tank foundation conditions, but is not likely to be as good in
inhibiting corrosion as a clean sand or concrete pad.
Tanks can be supported directly on penetration macadam over compacted backfill as
shown in Standard Form TAM-EF-364.
Like asphaltic concrete, do not use penetration macadam where corrosion protection
of tank bottom plates is required.
325 Foundations for Hot Tanks

This section provides guidelines for
hot tank bottom foundation design
leak detection
leak containment
Although the principles are applicable to any hot tank, the designs have been
tailored for tanks storing hot asphalt products in the temperature range of 200F to
600F.
These guidelines do not address tanks exposed to a large temperature gradient or
frequent heating and cooling cycles. For these conditions, give special consideration
to fatigue, thermal expansion, and creep.
The recommendations made here have the following goals in mind:
Minimize the costs for design, installation, and maintenance.

Provide a high quality installation that is safe, reliable, and easy to maintain.
Provide standardized designs which have the flexibility to meet local conditions
and requirements.
Include tank bottom retrofits in the design standards.
Under-tank Temperatures
In a temperature distribution study, high temperatures were found to exist several
feet below the bottom of a hot tank. Initial temperature profiles will vary from site-
to-site due to factors such as presence of moisture or different soil thermal
conductivity. Once a tank is put into hot service it may take months or years for the
ground temperatures to reach steady-state conditions. However, eventually high
temperatures will extend several feet below the tanks foundation.
Field tests also confirm high under-tank temperatures:
One company found temperatures of 160F at a depth of 30 inches below some
tanks after a relatively short period of service. If moisture is present or the
steady-state temperature condition has not been reached, this temperature could
be even higher.
In another instance, an asphalt tank resting on a refinery tank, wood-piled slab
foundation (wood piles are not recommended for hot tank foundations) had its
piles charred to a depth of several feet below the tanks concrete slab.
Under-tank Insulation. To counter the effects of high under-tank temperatures,
some designers have suggested using under-tank insulation. However, our
temperature distribution study indicated that insulation does not reduce steady-state
temperatures because the thermal gradient across the insulation has to be large for
the insulation to be effective.
Unless the insulations thermal conductivity is much lower than the soils, the
insulation will not work.
Also, soils thermal conductivity vary and may be even lower than those used
in our temperature study.
Therefore, although adding insulation may increase the time required to reach a
steady-state condition, eventually it will not ease the effects of high under-tank
temperatures.
Insulation can also generate other problems such as increased settlement,
moisture entrapment, tank bottom corrosion, and maintenance difficulties.
Note Do not use under-tank insulation.
Environmental Considerations
Many regulatory agencies now require release-prevention barriers and
leak-detection devices for tanks, including hot tanks. Release-prevention barriers
typically consist of under-tank liners.
Materials that are solid at ambient temperatures. Materials such as asphalt,
typically stored in a temperature range of 350F - 500F, or molten sulfur stored

above its melting point of 115C, are solid at ambient temperature. Because these
materials would solidify if leaked and because both asphalt and sulfur have been
used to pave highways, it is unlikely that any environmental harm would occur from
under-tank leaks. For these substances, it is recommended that tank owners
negotiate a leak containment solution on a case-by-case basis.
Materials that are liquid at ambient temperatures. MUse liners for hot
substances that are liquid at ambient temperature or are toxic if leaked.
Leak Detection and Containment

For leak detection, API 650 requires tank-bottom leakage be redirected to the tank
perimeter where the leakage can be observed. An undertank liner can both redirect
the flow for leak detection and also act as a release-prevention barrier or liner.
Note If leak containment is required, the preferred method is a double steel
bottom. See Figure 300-6.
Under-Tank Liners. For ambient-temperature tanks, plastic liners provide leak
detection and containment. However, high temperatures can exist several feet below
a hot tank. Use either a double bottom (metallic liner) or a concrete liner (described
below) for temperatures exceeding 250F.
Note Concrete is the liner of choice because it can be designed to resist the high
under-tank temperatures.
Clay, concrete and steel liners have been used for hot tanks. Base the choice on
economics, maintenance concerns, and local regulations.
Clay liners
Can withstand temperatures over 200F without melting, but they are
susceptible to drying and cracking unless kept continuously moist.
High under-tank temperatures drive moisture away causing clay liners to
crack.
Place it close to the water table to keep the clay moist and prevent
cracking.
Lay the clay liner inside the ring-wall and covered with chloride-free, dry
sand prior to tank construction (Figure 300-6).
Note Do not use clay liners unless required by law because they degrade when
subjected to the high under-tank temperatures.
Polymer-based liners including HDPE
Will melt or stretch and tear apart from the tanks weight or shifting soil.
Therefore, do not use plastic liners for hot tanks unless designed for stock-
side temperature.
Design all liners (including plastic liners) for stock-side temperatures.
Note Do not use plastic liners unless required by law because they degrade when
subjected to the high under-tank temperatures.

Elastomeric liners
Although most are only reliable to approximately 250F, Teflon can with-
stand 450F temperatures.
Heat-seamable PFA teflon (available in 60 to 90 mil sheets in 4' widths, by
100 or more feet long) could be used but has not been tried due to its high
cost.
Concrete as a Liner
Concrete may be an undertank liner or a release-prevention barrier if it
meets certain requirements.
American Concrete Institute publication ACI 350R-89, Environmental
Engineering Concrete Structures lists these requirements and
recommendations for structural design, materials and construction of
concrete tanks and other reservoirs.
Although permeability is not addressed, water tightness is. A water-tight
concrete liner should prevent an environmental release; however, local
regulators have the final say as to what actually constitutes an acceptable
release-prevention barrier.
In order to be water tight, the concrete cracking must be controlled by the
use of temperature and shrinkage reinforcement. These specifications are
given in ACI 350R-89.
Foundation Design for Hot Tanks

Designing with Concrete at High Temperatures. Concrete compressive strength
decreases as temperatures increase. Reduction in strength results from temperature,
moisture content, loading history, and the type of aggregate used. As the concrete
heats up, the aggregate and cement expand at different rates. This, coupled with the
different stiffnesses for the aggregate and the cement, creates a complex interaction.
For concretes with limestone or gravel aggregate up to 600F, the strength
reduction is very small.
However, concrete with other aggregates may have up to a 40% strength
reduction at 600F.
At temperatures greater than 600F, the cement starts to dehydrate and its
strength drops off more dramatically.
Therefore, for temperatures higher than 600F, consider special types of
cement (such as alumina cement)
Using alumina cement concrete for tank foundations with tank
temperatures below 600F is very costly and probably not necessary.
For temperatures required to tolerate under 600F
Regular concrete with an appropriate strength-reduction factor may be
used for foundations.
For tanks with temperatures in the range of 200F to 400F, use 4000 psi
concrete.

For tanks in the range of 400F to 600F, use 5000 psi concrete.
In both cases, design the foundation using a reduced strength of only 3000
psi to provide the required safety factor.
Concrete Mix. Use high quality concrete with a low water/cement ratio for hot
tanks. The following design mixture is recommended:
0.4 water-to-concrete ratio
a minimum of 490 lbs per cubic yard cement
a maximum of 5% entrained air
no accelerators (especially accelerators with chlorides)
Proper curing practice is essential and consists mainly of keeping the new concrete
surface damp for at least the first seven days. Locally available aggregate should be
acceptable because the design already takes into account the reduced concrete
strength at high temperatures.
Selecting Foundation Type. Figure 300-6 simplifies selecting a hot tank
foundation, taking into consideration the line, leak detection and other variables.
The selection chart refers to figures occurring later in this section.
Single Bottom Designs with Concrete Liners. Single-bottom designs with slabs
under the tank are shown in Figures 300-8 and 300-10.
Single bottom concrete slabs and/or ringwall foundations are recommended for hot
tanks because the slab:
1. provides a release-prevention barrier or liner under the tank. As such, it is
imperative that the concrete be properly reinforced. Using reinforced concrete
reduces the chances of differential settlement and failure.
2. reduces the possibility of moisture collecting under the tank bottom. Moisture
can accelerate corrosion or cause temperature variations that create high local
stresses on the shell-to-bottom welds and the bottom plates.
3. provides the opportunity to install leak-detection grooves that meet the
requirements of API 650. See Figure 300-9.
Install the concrete slab to cover the entire bottom of the tank. The concrete
foundation acts as a liner, creating a barrier which prevents groundwater
contamination. The foundation also includes leak-detection grooves which will
guide the leaking product towards the tanks periphery for easy detection.
Reinforce the concrete so that cracks cannot propagate and undermine the
concretes integrity.
As with any other design, include temperature steel in the ringwall and concrete
slab.
However, because of thermal gradients, place additional reinforcing steel in the
circumferential (hoop) direction near the outside edge.
If the tank is under 30 feet in diameter, it is less costly and more effective to use the
integral ringwall-slab design shown in Figure 300-8. Instead of a ringwall, a slab

Fig. 300-6 How to Select a Hot Tank with Leak Detection/Leak Containment
with thickened edges is used. The required reinforcing, leak detection, and thermal
considerations are the same as those for larger tank foundations.
A double steel bottom is the preferred method for leak detection/containment.
The design of Figure 300-10 includes an expansion joint to accommodate the
thermal growth of the slab relative to the ringwall. The temperature range for this
design is from 200F to 600F.
Note In Figure 300-10 a leak will not be contained, but will run out into the
secondary containment area. However, this is probably not a critical factor in the
protection of the environment because the leak is detected soon and can be stopped
and cleaned up quickly.
Figure 300-11 is an alternative to a slab under the tank. This design uses a curb to
provide more leak containment. However, it is probably no more effective than
other designs and probably more costly. Its use may be governed by local
authorities.

Designs for Tank Bottom Replacement or Retrofitting. When upgrading or

replacing the bottom of existing tanks for high temperature service, Figure 300-12
shows an economic and reliable method for providing a liner and leak detection.
A new concrete spacer, at least four to six inches thick, is poured over the old
tank bottom.
Reinforce the concrete liner according to ACI 350R-84 to provide water tight-
ness and to prevent excessive cracking.
Radial grooves are added for leak detection.
For substances that may not be considered hazardous, such as asphalt and
sulfur, welded wire mesh is adequate reinforcement in lieu of rebars because
cracking would not create environmental problems.
Designs Using Double Steel Bottoms. Figure 300-13 can be used for new tanks or
for replacing a tanks bottom plate. This design provides containment in the form of
a double steel bottom, with the tank bottom closest to the ground forming the liner
or release-prevention barrier. The system is built on compacted fill soil.
Hot Tank Anchoring

In general, tanks should be designed with a low H/D ratio so that anchoring is not
required for the seismic loadings specified by API 650, Appendix E. When it is not
possible to keep the tanks H/D ratio low enough (approximately 0.4 to 0.5 in
seismic Zone 4), anchors may be required.
The anchorage must be designed to accommodate the differential thermal expansion
in the radial direction between the tank and the slab.
Use the detail of Figure 300-14 when a hot tank requires seismic anchorage. It
allows for the different radial expansions that will occur between the tank and its
foundation without generating significant bending stresses in the anchor bolts.
Hot Tank Sumps

Emptying a hot tank for cleaning, inspection, maintenance, and repair, can be
difficult if the contents solidify or become hard to handle at ambient temperatures.
Therefore, tank owners often wish to install bottom sumps.
However, in hot tanks, the indiscriminate use and design of tank-bottom sumps or
appurtenances have led to failures due to the thermal expansion of the tanks
bottom. Presently, for sumps or appurtenances to perform reliably and without risk
of failure they must be designed on a case-by-case basis. One such concept is shown
in Figure 300-15.
Hot Tank Corrosion

Corrosion in hot tanks can occur anywhere water is in contact with the tanks
bottom plate. Most of the time, the high under-tank temperatures drive away
existing moisture, especially near the tanks center. However, in a location with
frequent rains, a high water table, or an area subject to frequent flooding, water may
be in contact with the tanks bottom.

Generally, any corrosion is limited to the tanks periphery, because that is the only
area where water can have lasting contact with the tanks shell and bottom.
The tanks edge may never become completely dry because of a phenomena known
as moisture pumping: as the water under the tank is heated, it rises, pushing the
water above it out of the way and drawing more water in to take its place. Moisture
pumping can be minimized by placing a tank well above the water table. Also, a
concrete pad or ringwall foundation should create an effective barrier, minimizing
moisture pumping.
For tanks in the temperature ranges being discussed, any water in contact with the
bottom plate will probably turn to steam. Although steam is less corrosive than
liquid water, its corrosive effects should not be discounted.
In existing tanks where the chime (the external part of the annular ring) sits in a
puddle of water, severe corrosion can be expected. With the combination of thermal
stresses and corrosion, there is a potential for failure at this critical shell-to-bottom
joint. Excavate the tank perimeter and drain it to assure that no standing water
collects around the tanks base.
Note The best way to reduce under-tank corrosion is to keep the tanks underside
dry. Raising the tank four to six inches above the adjacent grade including future
foundation settlement should reduce moisture contact and bottom-side corrosion.
Note Cathodic protection under hot tanks is not recommended because the
anodes life is greatly reduced at elevated temperatures.

Fig. 300-7 High-Temperature Tank Foundation with Leak Detection & Containment Using
Clay Liner
Tank Shell
Insulation
Tank Foundation Clean Dry Sand
(See Note 5)
Chamfer
Tank Bottom
Finished Grade.
Slope Away
From Tank
Clay Liner
(Claymax or Equal)
Note: Clay Liner Shall Compacted Fill

be Chloride Free
Fig. 300-8 High-Temperature Tank Foundation with Leak Detection for Small Tanks
Tanks < 30 in Diameter
Tank Shell
Insulation Leak Detection Groove

(See Foundation Plan)
Tank Foundation
(See Note 5)
Tank Bottom
Chamfer (See Note 6)
Finished Grade Slope

Slope Away
From Tank

Fig. 300-9 Hot Tank Leak Detection Foundations
40
Mini
mu m
5'0
R
Sawcut 3/4 Deep
1 Wide Grooves
1'0 Typ
Slope
8'0 Maximum
Spacing Typ
Repeating Pattern
Single Slope Configuration

(See Note 8)
Grooving is Typical for
Figures 300-8, 300-10, 300-12, 300-13
Concrete Slab
Typical
Inside Face of
Exist Tank Shell
4'0 Minimum
Slope Spacing Typ
Length of Grooves Sawcut

to be Determined by 3/4 Deep 1 Wide
Minimum Spacing Grooves
8'0 Maximum
Spacing Typ
Repeating Pattern
Cone Up Configuration
(See Note 8)
Grooving is Typical for
Figures 300-8, 300-10, 300-12, 300-13

Fig. 300-10 High-Temperature Tank Foundation with Leak Detection Tanks >20 in Diameter
Tank Shell
Insulation
Tank Foundation
(See Note 5)
Leak Detection Grooves
Tank Bottom (See Foundation Plan)
(See Note 6)
Slope
Chamfer
Finished Grade
Slope Away Compacted Fill
From Tank Concrete Slab
Smooth Ringwall Top Surface
& Use Paper Joint
Ties
Ringwall
Fig. 300-11 High-Temperature Tank Foundation with Leak Detection and Leak Containment
Tank Shell
Insulation
Tank Foundation
(See Note 5) Pea Gravel or
Sand Fill
Chamfer
Tank Bottom
Leak Detection
Gravel at
Drain Pipe Cap May Be
Drain
Used in Lieu of Valve
Finished Grade Slope
Ties
Concrete Slab

Fig. 300-12 Retrofit Existing with New Bottom to Include Leak Detection
Insulation
Install New Tank

Bottom by Slotted
Shell Method Concrete Spacer
(See Note 4)
Leak Detection Grooves

Leak Detection Slope (See Foundation Plan)
(See Note 7)
Fig. 300-13 High-Temperature Tank Foundation with Leak Detection and Leak Containment
Tank Shell
Insulation
Leak Containment Tank Bottoms
Concrete Liner
(See Note 9)
(See Note 4)
Tank Foundation Leak Detection Grooves
(See Foundation Plans)
(See Note 6) Slope
Chamfer
Finished
Grade
Compacted Fill
Ties
Ringwall

Fig. 300-14 High-Temperature Tank Anchor Detail
A. B.
Tank Shell
Anchor Bolt & Tank
Slotted Hole
Teflon Washer Anchor Bolt
Anchor Chair
Tank Shell
Tank Bottom

Fig. 300-15 Hot Tank Sumps
B Blockout
in Fdtn Matl d + 1
Metal Sump
To Center
of Tank Tank Shell Radial
Plan Growth
100% Penetration & d
Tank Shell
Fusion Welds at
Bottom Welded
These Locations
Insert PL
Metal
Sump
Bottom PL
Foundation
1 A O.D. Sump (d + 1)
B I.D. of Block-out (6 Max)
d = Expected Radial B = A + d + 2 Insulation
Growth of Tank
at Shell

Figure Notes
1. Concrete strength shall be Fc = 5000 psi for tank temperatures ranging from
400F to 600F, and shall be Fc = 4000 psi for temperatures from 200F to
400F. The design strength for concrete in all cases is assumed to be 3000 psi
due to the high temperatures affect on concrete strength.
2. Chloride salts shall not be added to the concrete to accelerate hardening. To
prevent corrosion, concrete shall not exceed 0.15 percent soluble chlorides in
accordance with the recommendation of American Concrete Institute 201.2R-77.
3. Reinforced concrete design shall follow ACI 318 requirements and ringwall
design guidelines as specified in this manual.
4. Spacer reinforcement shall be ASTM A-185 6 x 6 - W1.4 x W1.4 welded wire
reinforcement. Splices shall have a 6" minimum lap.
5. Edge of concrete surface shall slope away from the tank to prevent water infil-
tration under tank bottom.
6. Foundation should be up or single slope. Slope shall not be less than 2" in 10'.
7. Where grooves come to edge of tank notch existing steel for leak detection.
8. For small tanks, the 4' - 0" minimum spacing between grooves should be
reduced.
9. Where grooves come to edge of tank, a coupling shall be installed.
326 Foundations for Small Tanks

Small, Shop-welded Tanks
The size of shop-welded tanks is limited by what can be transported over public
highways or railroads. A concrete pad is the most desirable foundation for shop-
welded tanks. The pad provides a level surface for placing the tank, and allows for
anchoring the tank when required, and can be used for leak detection.
In good soil locations, unanchored small shop-welded tanks can be supported on
compacted granular fill foundations. A gravel pad does not provide as level a
surface as a concrete pad, but it is structurally adequate. Gravel or sand pads can be
subject to surface irregularities during tank placement. They can also shift, causing
voids underneath the bottom during operation.
Tanks With Design Pressures to 2.5 psig

API Standard 650, Appendix F, discusses the use of tanks with internal pressures to
2.5 psig. Such tanks must be anchored to resist the uplift forces induced by the
pressure.

As an example, consider a 100-foot diameter tank with 2.5 psig internal

pressure.
Pu = Pi (D2 /4) (144) - TDL
(Eq. 300-1)
where:
Pu = uplift force, lb.
Pi = tank internal pressure = 2.5 psig
D = tank diameter = 100 ft.
TDL = tank dead load (shell + roof) = 827,000 lb.
Pu = 2.5 (1002) (144/4) - TDL
= 2,827,000 lb. - 827,000 lb.
= 2,000,000 lb.
With a factor of safety against uplift of 1.5, then 2,000,000 (1.5)/4000 pounds per
cubic yard = 750 cubic yards of concrete needed to resist the uplift.
The above example, though oversimplified, points out the special foundation
requirements for this type of tank.
API Standard 650, Appendix F sets forth the appropriate safety factors to be used in
calculating the resisting force.
Small Tanks on Elevated Supports

When tanks are required to have a prompt leak detection system, positive leak
detection can be achieved by supporting the tanks on steel beams over a concrete
pad. This arrangement provides a clear area where leaks can be seen. This type of
foundation can generally be used for small tanks up to 20 feet in diameter. Elevated
tank foundations are more expensive than other types of small tank foundations.
Therefore, justify the decision to support the tank on an elevated foundation by an
economic comparison with other methods of secondary containment and leak detec-
tion.
Example Design Calculation for Determining Beam Spacing

Tank size: 20 ft. diameter 14 ft. high
Specific gravity of contents, s.g. = 1.0
Bottom plate:
Plate thickness, t = 0.25 in (ASTM A283)
Corrosion allowance, tc = 0.125 in
Allowable bending stress, Fb = 20,000 psi (API 650)
L = steel beam spacing, ft.

W = uniform load on bottom plate, psf

M = bending moment in bottom plate, lb.-ft.
S = section modulus of bottom plate, in3
t+t
W = H unit wt. water s.g. + -----------c- unit wt. steel
12
(Eq. 300-2)
0.25 + 0.125
= 14 62.4 1.0 + ------------------------------ 490
12
= 890 psf
2 2
WL 890L 2
M = ------------ = --------------- = 89.0L
10 10
(Eq. 300-3)
S = 2t2 = 2 0.252 = 0.125 in3

(Eq. 300-4)
M
F b = -----
S
(Eq. 300-5)
2
89.0L 12
20, 000 = -----------------------------
0.125
20, 000 0.125 1 / 2

L = ------------------------------------- = 1.53ft on center
89.0 12
Therefore, the beams must be spaced at 1.5 feet on center.
327 Berms and Gutters

Design requirements for the area outside the perimeter of large tanks include:
A minimum eight-foot wide sloped berm to drain liquids away from the tank
and to facilitate maintenance and painting.
For tanks 20 feet in diameter or less, berm width needs to be at least six feet.
The slope should be 2% minimum.
Dress the berm to protect it from erosion.
Use either a spray coating of suitable asphaltic binder material or a two-inch
minimum asphaltic concrete or other permanent paving material.

Tank grades that are properly constructed require little maintenance except
occasional oiling and clearing of gutters and drains.Selecting a good berm dressing
is particularly important from the maintenance point of view.
Plant mix asphaltic concrete dressings are the most durable types, but many
types of dressing using well-graded soils mixed with road oils have been
successfully used.
The type of dressing to use will depend on the availability of material and cost.
Asphaltic concrete is more expensive than oil-coated soils.
Refer to Section 700 of the Civil and Structural Manual for more information on
paving and grading.
328 Catch Basins and Sumps

Design catch basins for tank water draw-off, sumps, and tank bottom outlets for
tanks on concrete ringwalls to resist the hoop tension of the interrupted ringwall.
Design and construction details for concrete sumps, bottom outlets, and catch basins
are shown in Standard Drawings GC-Q1075, GC-Q78677 and GB-S78986,
respectively.
330 Grounding Considerations
331 Grounding for Aboveground Metallic Tanks

Chapter 6 of NFPA 78, Lightning Protection Code, provides guidance on
lightning protection of aboveground tanks. Metallic tanks should be grounded by
one of the following methods:
1. Set the tanks directly on earth, concrete or pavement. NFPA 78 specifically
states that vertical, cylindrical tanks at least 20 feet in diameter and resting on
earth or concrete, and tanks at least 50 feet in diameter and resting on
bituminous pavement, are properly grounded. Tanks with a secondary
containment membrane beneath the bottom are sufficiently insulated from the
ground to require bonding in accordance with Method 3 below.
2. Connect the tank to a grounded metallic piping system without insulating joints
or flanges. Piping will normally be insulated from tanks where impressed-
current cathodic protection systems are applied. See the Corrosion Prevention
and Metallurgy Manual for more details.
3. Bond the tank through a minimum of two ground terminals (rods) at maximum
100-foot intervals along the tank's perimeter.
For more information on lightning protection, grounding, and bonding, see Section
900 of the Electrical Manual, NFPA 78, Lightning Protection Code, or API
Recommended Practice 2003, Protection Against Ignitions Arising Out of Static,
Lightning, and Stray Currents.

340 Foundation Construction

The Company has installed many types of tank foundations over the years: oiled
sand or dirt pads, plank, crushed rock, rock, brick and concrete ringwalls, etc. More
recently it has used the ringwall design with secondary containment and leak
detection. This section will discuss what to watch out for during the construction of
the latter design, although most of the critical factors and checks will apply to other
designs as well. The remarks below apply both to new foundations and, during
bottom replacement, to the spacer installed between the old and the new bottom.
The foundation consists of a concrete ring on which the tank shell will rest. Inside
the ring is a layer of compacted fill. An HDPE membrane liner is stretched over the
fill and impaled on the reinforcing bars that stick up from the ring about 1 inches.
For bottom replacement, the membrane is placed on top of the old bottom (see
Section 342).
A concrete pad (or spacer, for bottom replacements) is poured on top of the
membrane liner. If the pad is to be reinforced with polypropylene fiber or wire
mesh, this material is placed on the membrane before the concrete is poured. After
the pour, grooves in a pie shape arrangement are cut in the pad to drain any liquid
leaking from the tank to the outside where it can be seen.
Standard Drawings GD-D1120 and GF-S1121 provide excellent illustrations of the
requirements for new leak detection bottoms and foundations.
341 Concrete Work

Dimension Checks
During construction of the foundation, critical dimensions such as diameters,
depths, levels, ringwall depth, fill depth, waterdraw basin dimensions, telltale line
location, etc., must be checked for accuracy against the drawings.
Excavation and Fill

Before Concrete is Poured. Any backfilling of the excavation made for the
foundation should be well tamped into place. The bottom of the excavation should
be checked for adequate compacting. Forming for the vertical walls of the
foundation should extend below the grade specified.
After Concrete is Poured. Backfill around the ringwall and waterdraw basin after
removal of forms should be well compacted.
Concrete for Foundation

Before ordering the concrete, check mix proportions and mix timing with concrete
subcontractor. Chloride salts should not be added to the mix to accelerate hardening,
and soluble chlorides should not exceed 0.15%, as recommended by the American
Concrete Institutes publication 201.2R-77 Guide to Durable Concrete. Also
check proportion of concrete to polypropylene fiber reinforcement material, where
used for the pad.

Before Pouring
Slump Test. Be sure you have cylinders on hand to perform slump tests.
Ringwall Forms. Before concrete is poured, the top of the ringwall forms should be
checked for level by survey: the elevation of the top of the concrete must be within
inch of the specified elevation at all points. In addition, elevations should not vary
by more than 1/8 inch in any 30-foot circumferential length, nor more than inch
about the entire circumference.
Reinforcing Bars. Before concrete is poured, check that the bars are the correct size
and dimensions and that they are placed according to the drawings and
specifications. The bars must be at least 1 inches away from the foundation forms
for adequate coverage when the concrete is poured.
Concrete Pad. If wire mesh is used as a concrete pad reinforcement instead of the
recommended polypropylene fiber, check that there are sufficient chairs to hold
the wire the proper distance above the fill or old bottom. Before pouring, check the
slope to ensure there will be sufficient concrete over the wire reinforcement.
During Pouring
Mix Consistency. Perform slump test and check that concrete is worked into all
areas so there are no voids or trapped bubbles of air.
Coverage, Concrete Pad. The minimum concrete coverage depth should be
checked against the specification.
After Pouring
Concrete Ringwall. Immediately after the ringwall is poured, elevations and
tolerances should be checked by survey. Swelling of the formed area usually results
in a slight lowering of the top edge of the form. A slight variation in the ringwall
diameter is not critical but any variation in the top of the ringwall and pad elevation
is. The height (top elevation) of the pad edge form should be checked for elevation
by survey, not by measuring from the top of the ringwall pour.
Check that drain pipes through the concrete ringwall are clear, not plugged.
Exposed Edges. All exposed edges of final pours should be chamfered. Minimum
thicknesses should be checked immediately following the pour.
Concrete Pad. After the forms are removed and needed patching completed on the
outside edge of the pad, check that the concrete patches or grout adhere properly.
When to Cut the Leak Detection Grooves. Saw-cutting of the grooves in the
concrete pad should be done as soon as the concrete is cured enough for foot traffic.
Usually this is 24 to 48 hours after the pour. This is the optimum time for ease of
cutting and to avoid broken edges. See Section 342 below for the proper method for
saw-cutting the grooves.

342 Installing the Secondary Containment and Leak Detection System

Together, the membrane liner and the grooves cut into the concrete pad are the
secondary containment and leak detection system. This section tells you what to
watch for during membrane liner installation. Also refer to the following additional
sources of information in the Tank Manual: Specification TAM-MS-1, Tank
Bottom Replacement and Membrane Placement; Specification TAM-MS-4763,
Membrane Liner for New Tanks; and Tank Manual, Section 250, Leak Detec-
tion and Containment.
When to Install the Membrane Liner

New foundations. The membrane is placed after completion of the concrete
ringwall, removal of the internal ring forms, and backfilling and compacting (to the
proper slope) of the area inside the ringwall.
Cone up bottom foundations. The membrane is installed under the waterdraw
basin prior to its pour.
Cone down bottom foundations. The center sump and sump liner along with the
telltale line from the sump liner to the standpipe outside the tank are placed prior to
membrane installation.
How the Membrane Liner is Attached

New foundations. The membrane liner is impaled over the concrete ring foundation
reinforcing bars extending vertically from the foundation (see Standard Drawing
GF-S1121).
Replacement bottoms. The membrane is attached to the old bottom at the shell by
adhesive/sealant and by impaling (see Standard Drawing GD-D1120). The old
center sump is cut out and replaced with a new sump and sump liner, and telltale
line run to a standpipe outside the tank for cone down bottoms.
Forming the Membrane Liner. The membrane liner should be level, smooth and
free of wrinkles as practical before the sheets are extrusion welded (or bonded)
together. Check extrusion welds (or lap joint adhesion) for bond and leakage. Bond
can be checked with a dulled ice pick, and leakage by vacuum test similar to that
used for welded steel plate seams.
On replacement bottoms, the membrane at the rat holes should be well sealed
with adhesive/sealant. (On bottom replacement jobs, rat holes are the cutouts in the
old shell that allow leaks to drain from the grooves in the concrete pad and out to a
gutter.)
Telltale Pipes. These pipes carry the liquid from leaks away from the tank to where
an operator can see it. On cone down bottoms, telltale pipes should be checked for
level and tested for leakage. The backfill should be tamped. On replacement bottom
installation of the telltale line, the area under the concrete ringwall (or area under
the shell) should be back filled with concrete to avoid local settlement.

Sump. Center sump elevation should be exactly to specification. The sump should
rest fully on well compacted soil. If the base under the center sump has any
tendency to shift or settle, an unformed, polypropylene fiber reinforced 4-inch thick
pad should be installed and checked for elevation before the basin is installed.
Leak Detection Grooves. Follow the rules below for grooves:
Grooves in the concrete pad are best made by saw-cutting. As an option,
floating the grooves while concrete is fresh has also given good results.
Grooves should line up and extend to the rat holes cut in the existing shell on
cone up bottom replacements. The last 12 to 15 inches will have to be chiseled.
On cone down bottoms, grooves shall stop 12 to 15 inches from the shell,
which will not have ratholes.
Grooves should extend to the distance from the shell that the concrete saw can
cut on replacement cone down bottoms.
The groove layout should be checked against proper drawing detail. Note the
difference between the cone up and cone down groove pattern.
343 Bottom-to-Foundation Seal

Before placing the new bottom plates (or annular ring), a band of sealant is placed at
the edge of the foundation or pad. This sealant prevents groundwater from entering
under the tank.
350 Tank Settlement

Tanks are relatively flexible structures which tolerate a large amount of settlement
without signs of distress. However, tank settlement has caused failures such as
inoperative floating roofs, shell and roof buckling damage, leaks, and loss of tank
contents. Foundation design, soil conditions, tank geometry and loading, as well as
drainage, all have a significant effect on settlement.
Large petroleum tanks are generally constructed on compacted soil foundations or
granular material, while smaller tanks are often built on concrete slabs. The
settlement covered in this discussion pertain to large tanks (over 50 feet in diameter)
because most large tanks are built on foundations where the thickness, elasticity and
compressibility of the foundation and subsoil layers can vary enough to produce
non-planar distortions when uniformly loaded. However, the basic principles apply
to all tanks, especially uniform settling and planar tilt.
When filled, tank contents will uniformly load the foundation beneath the tank as
the result of hydrostatic pressure in a disk pattern. However, the tank edge:
carries an increased load from the shell and roof weight.
can suffer loading effects such as twisting of the plates under the shall due to
shell rotation.
Note The tank edge is defined as that area of the tank which is comprised of the
tank shell, the roof supported by the shell, and the foundation directly beneath.

For these reasons, most settlement problems occur in the foundation that is under
the outside edge of the tank. Settlement problems are assessed by taking elevation
readings at the base of the tank. Nonetheless, failures have occurred from interior
settling that went undetected in elevation readings.
Settlement failure poses serious consequences to safety and surrounding property.
Until the mid 1950s, tanks were limited to about 200,000 bbls capacity. Since then,
capacity has increased to 800,000 and 1,000,000 bbl. Considering these tank sizes,
criteria must be available to ascertain the extent of settlement and correction
procedures.
351 Spotting Settlement Problems

Tank settling can be indicated by any of the following:
Roof binding on floating roof tanks.
Damage or early wear-out of floating roof seals.
Shell buckling in fixed or floating roof tanks.
Roof buckling in fixed roof tanks.
Loss of support in fixed-tank, roof support columns.
Cracking of welds.
Loss of acceptable appearance.
Over stressed piping connections
Accelerated corrosion due to drainage pattern changes on the outside of
the tank.
Inoperative or less effective drainage on the interior of the tank, especially
where cone-up, cone-down, or single sloped bottoms are used.
Increased susceptibility to seismic damage as a result of distorted, over stressed
or deformed bottoms.
Leaks in the bottom of shell.
The most serious failure results in leakage or loss of contents. The presence of even
a small crack in the tank bottom can be a serious threat to the integrity of the tank.
Several notable settlement failures have followed this sequence:
1. Development of an initial leak caused by a crack in the tank bottom.
2. Washed out foundation support immediately near the initial leak location,
causing the crack to grow from lack of support.
3. Increased leakage and undermining of the support under the tank. The bottom
plates separate from themselves or from the shell where the foundation has
washed away.
Prior to several incidents [1] leakage was seen emanating at the chime, but the
contents could not be pumped out before a major failure occurred.

352 Kinds of Settling

Tank settlement occurs in the following categories:
Uniform Settlement
Planar Tilt
Differential Shell Settlement
Global Dishing
Local Interior Settling
Sloped Bottoms
Edge Settlement
Uniform Settling
In this type of settling the soil conditions are relatively uniform, soft or
compressible, and a storage tank will slowly, but uniformly sink downward as
shown in Figure 300-16. Uniform settling poses no significant problems; however,
there are two important side effects.
Fig. 300-16 Uniform Settlement
Water Ingress. Water Ingress occurs when a depression or water trap is formed
around the tank's periphery where it meets the soil. When it rains, moisture
accumulates under the tank bottom near the shell or chime region and corrodes the
bottom.
Piping. Piping connected to the tank will eventually become over stressed by the
tank movement unless sufficient flexibility is designed into the piping system.
To assess the degree of uniform settlement, simply monitor elevations at the base of
the tank.

Planar Tilt
In this mode the tank tips as a rigid structure. (See Figure 300-17). Often planar tilt
accompanies uniform settlement. Planar tilt can be assessed from an external tank
inspection conducted by taking elevation readings at the base of the tank. The
following may occur as the tilt becomes severe.
Fig. 300-17 Planar Tilt Settlement
Appearance. The human eye is sensitive to vertical lines. With a relatively small
angle of tilt the appearance of a tank begins to look strange. The public or
employees may begin to question the safety of the tank and the operating and
maintenance practices of the owner. Planar tilt limited to D/50 is a reasonable
plumbness specification that provides an acceptable tank appearance.
Hydrostatic Increase. The tilt of the tank results in an increase in hydrostatic head
as shown in Figure 300-17.
If the increased stress causes the shell to exceed the design-allowable stress, there
are several solutions:
Lower the liquid level.
Operate the tank slightly above allowable stresses.

Reduced Storage Capacity. Because the maximum liquid level is often just
beneath the roof or overflow, the allowable liquid level may have to be reduced to
accommodate the planar tilt.
Ovalizing. If a tank tilts, the plan view will be an ellipse, shown in Figure 300-17.
Because floating roof tanks have specific clearances and out-of-round tolerances for
their rim seals to work properly, planar tilt can cause a seal problem. However, the
amount of planar tilt would have to be extreme for ovalizing to become a problem.
Differential Shell Settlement

Differential settlement, alone or in combination with uniform settlement and planar
tilt, results in a tank bottom which is no longer a planar structure. This type of
settlement problem can be assessed by taking elevation readings around the
circumference of the tank shell, where the bottom projects beyond the shell.
The readings can then be plotted as shown in the Figure 300-18. If the bottom of the
tank is planar, then a cosine curve may be fitted through the measured points.
However, if there is differential edge settlement, then a best-fit cosine curve can be
fitted to these points.
Differential shell settlement is more serious than uniform or planar tilt settlement
because deflection of the structure on a local scale is involved which produces high
local stresses. Differential edge settlement results in two main problems.
Ovalizing. As shown in Figure 300-19, differential settlement occurring in the tank
bottom near the shell produces an out-of-round condition at the top of tanks which
are not restricted in movement (e.g., a floating roof tank). One of the most serious
problems with bottom differential-edge settlement in floating roof tanks is the
operation of the floating roof. Because floating roof seals have specific tolerance
limits between the edge of the roof and the tank shell, ovalizing can interfere with
the operation or destroy the seal itself.
If the bending stiffness of the tank is much less than the extensional stiffness (thin
wall structure), then the theory of extensionless deformations may be used to
compute the relationship between differential settlement and radial deformation at
the top of the tank.
It has been found that with specific readings of settlement, the following finite
difference equation may be used to estimate ovaling:
2
DH N
r = --------- ------- S i
2 2
(Eq. 300-6)

Fig. 300-18 Differential Tank Settlement

Fig. 300-19 Problems Resulting from Shell Out-of-Roundness Due to Nonuniform Settlement
Derived from Hydrocarbon Processing, August, 1980. Pg. 102. Used with permis-
sion.
where:
i = station number of elevation reading taken at base of tank
r = radial shell displacement at top of tank
N = number of stations or readings
H = shell height at which radial displacements are calculated
D = tank diameter
S = measured settlement at ith location
x = circumferential shell coordinate
Shell Stresses. Non-planar, differential settlement may generate shell stress near the
top of the tank and may result in buckling of the upper shell courses. In the past, the
amount of differential settlement allowed was determined by arbitrarily limiting the
differential settlement to a constant, which represented a ratio of the settlement to
the span between consecutive settlement measurements. Figure 300-20 shows how
various structures, particularly buildings, are damaged when the slope represented
by the deflection-to-span ratio exceeds some value.
One commonly used limit [2] is
1
S = ---------
450
(Eq. 300-7)

Fig. 300-20 Limiting Angular Distortion Adapted from Berrum, 1963
:+(5(
where:
l = length between settlement readings, feet
S = allowable settlement
Local slopes limited to approximately l/450 to l/350 applied to tanks have proven
conservative, and result in tanks being releveled when further settlement could have
been tolerated.
The API 653 formula uses a factor of safety of two times:
2
y 1
S = .011 ------------
2EH
(Eq. 300-8)
Global Dishing
The entire tank bottom settles relative to the shell. This may occur singly or in
combination with other forms of settlement. There is no one form of global settling,
however, the majority of tank bottoms do tend to form a dished shape as shown in
Figure 300-21. There are several other common global settling patterns and investi-
gators have recommended criteria for each type as shown in Figure 300-22. [3]
The problems associated with general global settling are:
High stresses generated in the bottom plates and fillet welds.
Tensile stresses near the shell-to-bottom welds that may cause shell buckling.

Fig. 300-21 Dish Settling
Fig. 300-22 Normalized Settlement of Tank Bottom
Change in calibrated tank volumes (strapping charts and gauges).

Change in the drainage of the tank bottom profile and puddling when
attempting to empty tank.
The literature suggests maximum global dishing values that range from D/50 to
D/100 depending on foundation type, safety factor or empirical data. The value

stated in the 1st edition, of API 653 is D/64. For global dishing these values appear
to be reasonable. A 100 foot diameter tank using the provisions of Appendix B of
API 653 would have a total dish settlement of B=.37R where B is in inches and R is
in feet of 18.5 inches. However, for values of R less than 3 - 5 feet these limitations
are not really applicable to local settling as explained later.
The methods presented above are based upon the large deflection theory of circular
flat plates with edges that are not free to move radially. However, when the
difference in settlement between the center and the periphery of the tank is large,
there are indications that the bottom membrane does move inward radially or the
shell will be pulled in as shown in Figure 300-21. From theoretical considerations,
the difference in membrane stresses generated between a circular plate simply
supported with a fixed edge and an edge that is free to move radially is a factor of
about 3. [4] This means that the stresses will be 1/3 as high for bottom plates that
are free to slide as for those that are not. When the tank is loaded with liquid, the
bottom plates are probably held in place more securely; therefore, it may not be a
valid assumption to use the free edge condition.
For other modes of global settling it has been suggested [5] that different allowable
settlements be provided for the different configurations. This is shown in
Figure 300-22.
Local Interior Settling

Local settling that occurs in the interior of tanks often takes the form of depressions
as shown in Figure 300-23. Local interior settling poses similar problems to Global
Dishing and the proposed methods of assigning a tolerance are again based upon the
theory of large deflection. Some of the methods include a relaxation, when the
settling occurs near the tank wall, to take into account the freedom of the plate near
the shell to slide radially inward as the depression increases.
Fig. 300-23 Bottom Settlement From API 653, Figure B-7 & B-8. Courtesy of American Petro-
leum Institute.

Note that the tank fabrication process leads to buckles and bulges in the bottom
plates. When the tank is filled with liquid, these tend to level out, but often reappear
when the liquid is removed. Most of the models currently proposed for developing
settlement criteria do not take into account the initial waviness of the bottom.
This type of settling is inevitable in compacted earth foundations because soil
composition and thickness varies under the tank. Deformations are usually formed
gradually, without sharp changes in slope, so that the bottom plates are adequately
supported. Risk of failure from this type of settlement is minimal unless there are
serious problems with the welding integrity.
When large voids form under the tank bottom, the bottom plates may lift off the soil
completely as shown in Figure 300-23. Although this is not usually a problem, a
large void can lead to localized rippling effects. The tank releveling section covers
the problems associated with filling these voids with grout.
Sloped Bottoms
The previous settling discussions apply to flat bottom tanks; however, many tanks
have slopes intentionally built into the bottom. They fall into three categories:
1. Single slope
2. Cone up
3. Cone down
Because the design slope of these bottoms averages about one inch in ten feet, they
can still be considered flat bottoms and the previous sections apply.
However, one special situation arises when the bottom is sloped: Cone up bottoms,
subject to general dish settlement, can tolerate more total settlement than either flat
bottom, cone-down, or single-slope bottoms. As settling occurs, the bottom
compresses and becomes flat. As the soil settles below the tank, the compressive
stresses that were generated become relieved until the shell base becomes cone
down, approximately equal to the magnitude of the original cone up condition. See
Figure 300-24.
However, if the initial cone-up slope is significant, the settling relatively uniform,
and the bottom constructed with lap welded joints, a phenomenon known as rippling
can occur, usually during the hydrostatic test on newly constructed tanks. Because
of the linear layout of bottom plates and the use of fillet welds, a crease or a fold can
form, covering large parts of the diameter, as shown in Figure 300-24. The ripples
are typically unidirectional and occur in the long direction of the bottom plates. The
crease may be very severe (a radius curvature of approximately one foot is not
uncommon) and indicates that yield stresses have been exceeded. The ripple can act
as a stiffening beam and cause increased differential settlement and bottom failure.
The allowable settlement of cone up should be more than twice that of a flat or
otherwise sloped-bottom tank. The maximum slope should be inch per 10 feet to
avoid rippling.

Fig. 300-24 Tank Bottom Ripples
Edge Settlement
Edge settlement occurs in the bottom plates near the shell as shown in Figure
300-25. It is difficult to determine this condition from the exterior of the tank;
however, seen from inside the tank, this is one of the most obvious forms of settling.
Edge settlement occurs frequently in tanks that have been built on grades or
compressible soils. If the soil has not been compacted sufficiently or becomes soft
when wet, the probability of edge settlement increases. Edge settlement is mainly
due to increased loading on the foundation at the periphery from the weight of the
steel. Usually the foundation has not been extended far enough beyond the tank
radius to prevent lateral squeezing of the foundation (see Figure 300-25).
Edge settling can occur locally in soft spots around the edge of the foundation;
however, it usually involves a rather substantial portion of the tank. Edge settlement
is rarely seen in tanks that are constructed on reinforced concrete ringwall
foundations. It is more common where the tank is built on a crushed stone ringwall
foundation.
The two fillet welds between the annular plate, shell, and the bottom plates induce
stresses into the annular plate that cause upward bulges. Not strictly edge
settlement, these bulges may contribute to it by creating an initial slope in the
annular plate which in turn sets up residual stresses that cause the tank bottom under
the shell to apply greater downward pressure on the soil. The initial slope may be
attributed to edge settlement when it was caused by the welding. Proper weld
procedures, careful selection of the welding sequence for all welds in the bottom
annular plate, and careful fitup should minimize this problem.

Fig. 300-25 Edge Settlement From API 653, Figure B-5. Courtesy of American Petroleum Institute.
353 Settlement Criteria

To date there is no appropriate method for estimating tolerable edge settlement.
There are, however, numerous tanks in service showing edge settlement with
magnitudes of 6 to 18 inches over a span of 1 to 2 feet and functioning without leaks
or failures.
Edge settlement is unlike other kinds of settling. API 653 and other proposals are
based upon a model that is similar to the dishing models described above. Because
this type of settlement involves substantial yielding of the bottom plates (apparent
from the large deflections over short spans), any model that uses an allowable stress
basis for limiting settlement is probably extremely conservative. A strain-limiting
approach may be more appropriate.
The following two figures (Figure 300-26 and Figure 300-27 can be used to deter-
mine the maximum allowable edge settlement for areas with bottom lap welds
approximately parallel to the shell (Figure 300-26) as well as perpendicular to the
shell (Figure 300-27). The maximum allowable edge settlement for areas with a lap
weld at an arbitrary angle to the shell can be determined by using the equation:
B = Be (Be Bew) x sin

(Eq. 300-9)

where Bew and Be are from Figures 300-26 and 300-27 respectively, and is the
angle of the weld to a tank centerline (see Figure 300-28).
Fig. 300-26 Maximum Allowable Edge Settlement for Areas with Bottom Lap Welds Approxi-
mately Parallel to the Shell From API 653, Figure B-10. Courtesy of American
Petroleum Institute.

Fig. 300-27 Maximum Allowable Edge Settlement for Areas with Bottom Lap Welds Approxi-
mately Perpendicular to the Shell From API 653, Figure B-11. Courtesy of Amer-
ican Petroleum Institute.

Fig. 300-28 Edge Settlement with a Lap Weld at an Arbitrary Angle to the Shell From API 653,
Figure B-12. Courtesy of American Petroleum Institute.
354 Designing for Settlement

Depending on the degree and type of settlement expected (determined from similar
installations in the area or from soil surveys), there are several means of designing
for expected settlement with increasing effectiveness:
1. Standard lap-welded bottom
2. Annular plates with lap-welded bottom
3. Butt-welded bottoms
These construction methods increase in effectiveness (1-3), and they also increase in
price. Unless needed for reasons high settlement, the butt-welded tank bottom is
generally ruled out on a cost/benefit basis. Because the standard lap welded tank
bottom is the most economic, there is a tendency to use this design for locations
even where significant settlement is expected.
Additional construction measures can be more effective, such as deeper levels of
soil compaction, crushed stone ringwalls, reinforced concrete ringwalls or slabs on
ringwall foundations.
The use of annular plates reduces edge settlement. The use of concrete ringwalls
virtually eliminates edge settlement.

355 Releveling Tanks

Releveling tanks is a common procedure for correcting excessive settlement
problems such as buckling shell plates, leakage in the bottom plates, excessive out-
of-round and high stresses. When floating roof tank bases have experienced
differential settlement, the roofs can bind and seals may be damaged or ineffective.
Frequently, releveling causes the tank to reassume a round shape. Tanks that have
been buckled due to settlement or tanks that have been constructed with initial out-
of-round are usually not improved by releveling.
Releveling Methods
Some companies specialize in tank releveling. Deal only with reputable contractors
who have carefully planned a shell-releveling procedure which has proven effective.
All releveling procedures should include these factors:
For floating roof tanks, the roof should be supported from the shell to prevent
excessive stresses and the possibility of cracks occurring from differential
movement. Figure 300-29 shows one way of supporting the roof.
Fig. 300-29 Floating Roof Support

When tank jacking methods are used, it is possible to jack tanks up

approximately 10 feet high, allowing for bottom inspection, cleaning, removing
contaminated soil where leakage has occurred, rebuilding of the foundation if
necessary, or coating from the underside.
Support must be supplied for fixed-roof supports so that roof buckling and
damage does not occur.
The amount of differential jacking must be controlled so that shell buckling or
weld damage in the corner welds, or in the bottom plates, does not occur.
In all tank releveling procedures large groups are involved and mistakes could
cause injuries or unanticipated costs. Any work of this nature should be care-
fully reviewed for safety, environmental concerns, and good practices. The
owner should also be convinced that those performing the work have direct
experience using the proposed methods.
A releveled tank should be hydrostatically tested. Testing may not be necessary
in a few cases such as small tanks where the shell stresses are low or there was
very limited jacking.
Corrected piping should be disconnected if releveling will produce excessive
stresses causing equipment damage. Underground piping connections to the
tank should be exposed for monitoring.
Shell Jacking. Shell Jacking is a common releveling method where lugs are welded
to the shell near the base as shown in Figure 300-30. Typical spacing is about 15
feet. Once the lugs are in place and a suitable jacking pad set up, jacking proceeds
around the tank circumference in small increments. Jacking in small increments
prevents warping the bottom excessively out of plane. Shims are installed as the
jacks are moved around and the tank can be raised to any desired elevation. The
tank bottom will sag down somewhat, but will not cause structural problems with
the bottom welds if the welds are sound.
Typical specified tolerances average about inch of level for any measured point
on the tank perimeter at the base.
Contractor responsibilities include:
Furnish, design, install, and remove lugs.
Remove any weld arc strikes and ground out remaining slag.
Recommend the prior loading under each shimmed area to prevent foundation
damage and settling. (Recommended shim spacing is 3 feet.)
Propose if and how sand or grout should be applied to low points under the tank
bottom.
Monitor radial tolerances when correcting an out-of-round tank.
Provide complete written procedures for all work to be undertaken.

Fig. 300-30 Jacking Lugs Used on Large Tanks
If the jacking exposes a large area under the tank, applying a flowable grout or sand
layer will provide a planar foundation for the tank to rest on. However,
miscellaneous injection of grout through holes cut into the bottom plates is usually
ineffective or makes the situation worse.
If the work is meant to correct out-of-round, require frequent monitoring of the
radial tolerances as well as the effect of releveling on these tolerances. At least eight
equally spaced points at the top of the shell should used for monitoring. Elevations
as well as radial measurements should be made before and after the work.
A hydrostatic test should be conducted after the tank is releveled.
Under-the-Shell Releveling Method. The Under-the-Shell releveling method uses
jacking under the bottom of the shell. Small pits are excavated to hold the jack
under the tank shell. Figure 300-31 shows a typical jack arrangement for this
method. The principle objection to this method is that pits must be excavated
beneath the tank shell. In soil foundations, this may cause a loss of compaction in
the order of 40 -50%. [6] Another problem is that the spacing for shims and for jack
points must be greater than the shell-jacking method and therefore would provide
higher soil stresses while the work is in progress.
The same procedures, specifications, precautions and testing as covered under shell
jacking should be observed.
Tank Leveling by Pressure Grouting. This method, often called sand pumping, is
used to force low spots or settled areas upward. This method can be used to raise
small or large areas where tank bottoms are low. The contractor forces sand or grout
under pressure into the area to stabilize the bottom plates. Where the involved areas
are small and numerous, this method is usually ineffective because the mixture will

Fig. 300-31 Jacking Pit Dimensions
flow through the areas of least resistance and lift the plates even further. It also
causes the tank to rest on points rather than uniformly.
However, there are some cases where grout can be used effectively: pressure
grouting has been effectively used to level areas under fixed roof supports, for
example.
A tank owner considering this method should examine a step-by-step proposal from
the contractor to assure that good practices are involved and that all safety and envi-
ronmental regulations are considered. Before cutting the bottom to inject grout,
precautions must be taken to handle the possible existence of flammable liquids or
toxic substances that could have been stored or leaked in the past.
360 References
1. Cummiskey, B. J., Impoundment Liner Testing - Western Producing Oil
Cleaning Plant, June 30, 1983, Materials and Equipment Engineering Unit
File 25.6.
2. Klein, L. J., Storage Tank Containment Membrane TestsEl Segundo,
December 7, 1983, Materials and Equipment Engineering Unit File 6.85.

3. Stofanak, R. J., Storage Tank Containment Membrane TestsEl Segundo, April

3, 1985, Materials and Equipment Engineering Unit File 6.85.
4. Rippel, T. E., Permeability Testing Flexible Membrane Liners, February 28,
1986, Materials and Equipment Engineering Unit File 25.06.01.
5. Rippel, T. E., Immersion Testing of Flexible Membrane Liners for Secondary
Containment, May 30, 1986, Materials and Equipment Engineering Unit
File 6.85.
6. Kmetz, J. H., Adhesives Testing for Secondary Containment Membrane
Systems, December 3, 1987, Materials and Equipment Engineering Unit
File 56.1.
7. Environmental Protection Agency, Document EPA-600/2-88/052, Lining of
Waste Containment and Other Impoundment Facilities, Appendix K
8. James S. Clarke, Recent Tank Bottom and Foundation Problems, Esso Research
and Engineering Co., Florham Park, NJ 1971.
9. DeBeer, E. Foundation problems of petroleum tanks, Annal. lInst. Belge
Petrole 1969 6 25-40.
10. DOrazio and Duncan, Differential Settlements in Steel Tanks Journal of
Beotechnical Engineering Vol 113, No 9, 12/4/86.
11. Timeshenko, Theory of Plates and Shells, 2nd edition, Table 82.
12. Timothy B. DOrazio and James M. Duncan, Differential Settlements in Steel
Tanks Journal of Geotechnical Engineering, Vol 113, No. 9, September, 1987
ISSN 0733-9410/87/0009-0967/$01.00.
13. James S. Clarke, Recent Tank bottom and Foundation Problems, Esso Research
and Engineering Co., Florham Park, NJ 1971.

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300 Foundation Design and

310 Soils Considerations 300-3

Chevron Corporation 300-1 July 2000

342 Installing the Secondary Containment and Leak Detection System

July 2000 300-2 Chevron Corporation

310 Soils Considerations

311 Designs to Compensate for Settlement

Pascagoula DesignCone Up Bottom

Fig. 300-1 Cone Up Tank Bottom ConfigurationPascagoula Refinery

Tank bottom plates are placed in a cone up configuration to compensate for

Cone Down BottomCenter Sump Design

Chevron Corporation 300-3 July 2000

320 Foundation Design

321 Environmental Requirements

322 Design Loads and Forces

July 2000 300-4 Chevron Corporation

Chevron Corporation 300-5 July 2000

Small diameter tanks are more susceptible to overturning than large

323 Foundation Types

July 2000 300-6 Chevron Corporation

Chevron Corporation 300-7 July 2000

300 Foundation Design and Construction

protection. significant settlement is

A drawback with crushed

300 Foundation Design and Construction

300 Foundation Design and Construction

6. Leak detection and

3. Construction material 2. Tank cannot be

3. Allows for tank 3. Good soils information

4. Leak detection and more difficult to install.

300 Foundation Design and Construction

Concrete Ringwall Design

July 2000 300-12 Chevron Corporation

Crushed Stone Ringwall Design

Concrete Slab Foundation Design

Compacted Granular Fill Foundations

Chevron Corporation 300-13 July 2000

Fig. 300-3 Granular Fill Foundation with Steel Plate Band

Pile Supported Concrete Foundations

July 2000 300-14 Chevron Corporation

6. Design the pile cap and concrete slab.

Ringwall Foundation Design Example

Fig. 300-4 ExampleRingwall Foundation Design (1 of 11)

ACTIVE SOIL PRESSURE

Legend for this figure is on the next page

Chevron Corporation 300-15 July 2000

Fig. 300-4 ExampleRingwall Foundation Design (2 of 11)

Figure 300-4 continues on the next page

July 2000 300-16 Chevron Corporation

Fig. 300-4 ExampleRingwall Foundation Design (3 of 11)

Projected differential settlement = negligible

Figure 300-4 continues on the next page

Chevron Corporation 300-17 July 2000

Fig. 300-4 ExampleRingwall Foundation Design (4 of 11)

Case II. DL + Product + EQ

Figure 300-4 continues on the next page

July 2000 300-18 Chevron Corporation

Fig. 300-4 ExampleRingwall Foundation Design (5 of 11)

0.5 3424 120 2.5 2

c. Torsion and Bending Moment

Since the tank shell will be placed nomi-

= 4.22 ( 120 2 ) = 253 kip-ft