STI ACT-100 User manual

FRP COMPOSITE STEEL
UNDERGROUND STORAGE TANKS
INSTALLATION INSTRUCTIONS
OCTOBER 2014
R913
1.0 EXCAVATION AND BEDDING
1.1 The bottom of the excavation shall be
covered with a minimum of 12 inches (305
mm) of bedding, suitably graded and leveled.
Bedding and backfill material surrounding the
tank, to a width and depth of 12 inches (305
mm) all around the tank, shall be clean
material.
1.2 Where anchoring by means of a concrete
pad, the tank shall not be placed directly on
the pad. Bedding material at least 6 inches
(152.4 mm) deep must be spread evenly over
the dimensions of the pad to separate the
tank from the pad.
1.3 Bedding and backfill material shall consist of
homogenous pea gravel, crushed stone,
clean sand, natural earthen materials, or
excavatable flowable fill. Crushed stone,
clean sand and natural earthen materials
shall be capable of passing 100% through a
1/2 inch (13 mm) sieve and no more than
12% by dry weight through a #200 sieve
(0.0029 inch (0.0754 mm)). Pea gravel shall
be no larger than 3/4-inch (19 mm). Flowable
fill shall meet the National Ready Mixed
Concrete Association for Controlled Low
Strength materials (CLSM) with strength
ranging from 70 – 150 psi and shall be
installed in accordance with good engineering
practice. The materials shall be free of all
foreign materials, such as but not limited to,
bricks, metals, concrete and plastics.
1.4 The backfill material may be from the tank
site if it meets this description, or it may be
delivered to the site from another source.
1.5 Sand or natural earthen materials used as
backfill shall be placed into the excavation in
12-18 inch (305-458 mm) vertical lifts,
compacted after each lift, at least 60% up the
vertical height of the tank.
1.6 If earthen material from the site, or other
earthen material, is to be used as bedding or
backfill material, a minimum of four 1 cu.ft.
samples shall be taken from different locations
which are representative of the backfill material
and the site. Samples shall be sieved to
determine if the material complies with this
specification.
1.7 In a tidal area, the tank "bedding" material shall
be crushed stone or pea gravel. Sand and
natural earthen material may be used only if
measures are taken to prevent washout of
material during the design life of the system.
2.0 AIR TEST AT JOB SITE
2.1 Temporary plugs and thread protectors
installed by the manufacturer shall be removed.
Apply compatible, non-hardening pipe sealant
to internal bushing threads. Permanent metal
plugs shall be installed at all unused openings.
2.2 The nylon bushings in the tanks shall not be
removed from the unused openings. Plugs
used to temporarily seal the tank for the
aboveground air test, but later removed for pipe
installation, shall not be over-tightened. Do not
cross thread or damage the nylon bushings
when replacing plugs or installing required tank
piping.

2.3 Test pressure shall be maintained at, without
exceeding, 5 psig (34.5 kPa) while a soap
solution is applied to the area of pipe
connections and welds.
2.4 Dual wall tanks require different air pressure
testing procedures. Do not connect a high
pressure air line directly to the interstitial
monitoring port. A factory applied vacuum
within the interstitial space can be used in lieu
of, or in addition to, the air test procedure.
Consult tank fabricator for air test
recommendations. Do not apply a vacuum to
the primary tank or a single wall tank. PEI/RP
100-00 also provides guidelines.
2.5 Take necessary safety precautions during air
tests. Do not leave tanks unattended while
under pressure. Avoid standing at the head
of the tank, especially while applying air
pressure. Use an air-pressure relief valve.
3.0 FRP LAMINATE INSPECTION
3.1 Before placing the tank in the excavation, all
dirt clods and similar foreign matter shall be
cleaned from the tank.
3.2 Visually inspect the tank for damage. Pay
particular attention to areas where laminate has
been gouged or abraded. Mark all areas which
appear damaged for repair. Any section of the
laminate, which has been damaged beyond the
surface of the laminate, shall be tested for
holidays. This shall be done with a holiday
detector set at a minimum 10,000 volts.
3.3 Coat all holidays, damaged laminate, and/or
exposed steel surfaces using touch-up kit
furnished by tank supplier. Follow
manufacturer's instructions for mixing and
application of resin. (See Section 9 for
procedure.) All holidays shall be retested at
10,000 volts.
4.0 TANK HANDLING & PREPARATION
4.1 Controlled off-loading of the tank shall be
allowed.
4.2 If the tank is fabricated with fiberglass
reinforced polyurethane laminate, it has been
delivered with a protective material installed on
the tank. This material must remain on the
tank and shall not be removed. Before placing
the tank in the excavation, all dirt clods and
similar foreign matter shall be cleaned from the
surface of the tank. Set the tank on the ground
such that the protective material is between the
tank and the ground.
4.3 Equipment to lift the tank shall be of adequate
size to lift and lower the tank without dragging
or dropping to prevent damage to the tank or

the coating.
4.4 Tank shall be carefully lifted and lowered into
the excavation hole by use of cables or
chains of adequate length attached to the
lifting lugs provided. A spreader bar shall be
used where necessary. Under no
circumstances shall chains or wire rope slings
be used around the tank shell.
4.5 Follow label instructions including those at
tank openings.
4.6 This tank requires venting. Refer to
applicable local codes and PEI RP-100 for
proper installation.
5.0 ANCHORING
5.1 High water tables or partially flooded
excavation sites exert significant buoyant
forces on tanks. Buoyant forces are partially
resisted by the weight of the tank, the backfill
and the pavement atop the tank. Additional
buoyant restraint, when required, shall be
obtained by using properly designed hold-
down straps in conjunction with concrete
hold-down pads or deadman anchors. The
use of steel cable or round bar as hold-down
straps on the tank is prohibited.
5.2 If a metallic hold-down strap is used, a pad of
inert insulating di-electric material must be
used to insulate the hold-down strap from the
tank. The separating pad shall be wider than
the hold-sown straps, which will prevent direct
contact between the straps and the tank shell.
This pad is not required if the hold-down strap
is fabricated from non-conductive material.
5.3 Ballasting the tank may be necessary. When
water is used as the ballast material, it shall
only be potable water and shall not remain in
the tank longer that 60 days. During
construction, adequately vent all tank spaces.
If product is used as ballast, proper precautions
must be taken to prevent fires, spills, leaks, and
other associated accidents. Monitor product
level frequently to ensure there has been no
unaccounted loss of product. Do not over
tighten hold-down straps beyond snug and do
not re-tighten hold-down straps after ballasting.
6.0 BACKFILLING
6.1 Homogeneous backfill material similar to the
bedding material shall be carefully placed
around the entire tank to create a uniform
homogeneous environment. Avoid damage to
laminate especially where tamping is required.
6.2 Installing and tamping backfill along the bottom
sides of the tank shall ensure that the tank is
fully and evenly supported around the bottom
quadrant.
7.0 FINAL AIR TEST
7.1 Install required tank piping using compatible
non-hardening sealant, taking care not to cross
thread or damage the nylon bushings. Torque
of 400 to 1,000 ft-lbs (542.3 to 1355.82 N-m.)
shall be required to fully insert pipe.
7.2 Where air or hydrostatic testing is required after
installation, the pressure applied shall not be in
excess of 5 psi (34.5 kPa) as measured at the
top of the tank. A soap solution shall be
applied around pipe connections while air test is
being performed.
8.0 ELECTRICAL ISOLATION
8.1 All openings shall be isolated where electrical
accessories will be installed such as
submersible pump, monitoring equipment and

all other grounded electrical devices.
8.1.1 Prior to backfilling to top of tank, all openings
shall be visually inspected to assure that the
di-electric isolation (nylon bushings or flange
gaskets), where furnished, remains in place.
Where flanged openings have been used,
isolation of the flange gaskets shall be
confirmed with a continuity tester. Contact
with the tank shall be made with the inside of
the tank, or possibly at the lift lug, if steel is
exposed, prior to application of the lift lug
cover. No current shall pass through the
factory installed flange gaskets. Isolation of
the fittings is required to assure tank integrity.
8.2 If the tank is to be installed near an
impressed current system, the effect of the
system must be considered on the ACT-100®
tank. The corrosion consultant must consider
including the ACT-100®tank into the design
of the impressed current system.
9.0 SEALING OF PIPE CONNECTIONS,
LIFTING LUGS AND REPAIRS
9.1 Clean areas to be repaired through removal
of surface rust, dirt, contaminants, and
disbonded laminate. The laminate and
surface coat surrounding all holidays,
laminate flaw areas, lift lugs and/or exposed
steel areas shall be surface prepared by
using a coarse grit sandpaper or grinder.
(Refer to SSPC SP-2 "Hand Tool Cleaning"
or SP-3 "Power Tool Cleaning" for additional
guidance). This process shall remove all
glossiness from the surface surrounding the
repair area within 6 inches (152 mm) of the
holiday. Repair the area by using the repair
kit supplied by the manufacturer.
9.2 During the installation process, steel can
become exposed at the lift lugs due to
handling of the tank or at the interface
between the steel tank and either the nylon
bushing or gasket. These areas must be
repaired by one of the following methods.
9.2.1 A di-electric cap, if supplied by the
manufacturer, shall be placed over each lift lug.
First, prepare the surface of the tank to be
bonded to the cap in accordance with
paragraph 9.2. Apply the cap to the tank in
accordance with paragraph 9.2.1.1 or 9.2.1.2).
9.2.1.1 Place cap over lifting lug. Pre-mix resin with
catalyst and apply around the cap and the
tank surface immediately adjacent to the cap.
Bond the cap to the tank with two layers of
fiberglass mat previously saturated with resin.
Roll out all air bubbles and air pockets, or as
an alternative, see paragraph 9.2.1.2.
9.2.1.2 Pre-mix resin with filler material and catalyst.
Apply generously to tank surface at lift lug
and to bottom of FRP cap. Place cap over lift
lug. Apply additional resin with filler and
catalyst around edges of cap to seal. Allow to
cure.
9.2.2 As an alternative to Paragraph 9.2.1, exposed
steel at the lift lugs may be covered with the
laminate via the repair kit supplied by the
manufacturer.
9.2.2.1 Follow the manufacturer’s instructions given
in the repair kit.
9.3 After application, the installer shall verify that
the repair work has cured (adequate
material hardness and solidification) prior to
backfill.
9.4 After an air test has established tightness,
tank fittings shall receive a coat of resin prior
to backfill. (Refer to Section 9 for surface
preparation). Resin coating shall include the
entire plug on unused fittings.
9.5 Follow temperature guidelines supplied by the
manufacturer for proper catalyst/resin ratios
and recommendations. Ideally, exterior
temperature shall be within the 60-80oF (15.5-
26.6oC) range. Temperatures below 50oF
(10oC) shall require an external heat
source to enable a chemical reaction to
proceed.

10.0 FINAL BACKFILL
10.1 Homogeneous backfill similar to bedding
material shall be carefully placed around the
entire tank and to a depth of at least one
foot (305 mm) over the tank. (See NFPA
30 and state or local codes for a minimum
depth of cover required).
10.2 If laminate damage occurs after holiday
testing or during backfill operation, repairs
shall be made in accordance with Section 9.
11.0 OPERATION LIMITATIONS
Operation of the tank above 120EF (49EC)
requires the use of specific components
and materials. The tank manufacturer must
be notified, prior to tank use, of the owner’s
intent to operate this tank above 120EF
(49EC) so that proper components and
materials can be incorporated.
11.1 When the product stored is heated, the
temperature inside the tank shall be
constantly monitored to assure the
maximum allowable temperature is not
exceeded.
12.0 MAINTENANCE
12.1{The primary tank shall be inspected monthly
for the presence of water. Inspection shall
take place at the lowest possible points
inside the primary tank. Remove any water
found. Water and sediment in fuel can
cause plugging of filters. Also, bacterial
growth, originating from the fuel, can cause
filters to plug and corrosion of tanks and
lines. For procedures on how to check for
the presence of water and removal of water,
refer to the STI R111, Storage Tank
Maintenance. For copies of the RP and
more information, please go to
www.steeltank.com.
12.2 Tank must be installed within one year of
delivery from tank manufacturer. If tank is not
installed within this time period, contact tank
manufacturer to recertify the tank.
12.3 Safety considerations and controls should be
established prior to undertaking physical
activities associated with USTs. Some
hazards associated with USTs are, but not
limited to, confined space entry, cleaning,
inspection, moving and any other aspect of
in-service work.
12.3.1 Contact tank manufacturer before moving
tank for information on recertifying tank for
continued use.
Disclaimer
These instructions are intended only as an aid to tank
installers who are knowledgeable and experienced in
underground tank installation. Compliance herewith
does not necessarily meet the requirements of
applicable federal, state and local laws, regulations
and ordinances concerning tank installation. STI
makes no warranties, express or implied, including but
not limited to, any implied warranties of merchantability
or fitness for a particular purpose, as a result of these
installation instructions.
Contact STI for the latest version of these Installation
Instructions or visit the STI website at www.steeltank.com.

FRP COMPOSITE STEEL
UNDERGROUND STORAGE TANKS
INSTALLATION CHECKLIST
R913
944 Donata Court
Lake Zurich IL 60047
Phone: [phone]
JUNE 2010
Note: This checklist includes certain key steps in the proper installation
of the ACT-100®tank and is intended only as an aid to tank installers
who are knowledgeable and experienced in underground tank
installation. Compliance herewith does not necessarily meet the
requirements of all applicable federal, state, and local laws, regulations
and ordinances concerning tank installation.
Owner of Tank:
Location of Tank:
CHECK( )
HANDLING
The handling equipment is of adequate size and
capacity to lift and lower the tank without dragging
or dropping.
The repair of any damaged laminate areas has been
made in accordance with installation instructions.
Prior to storage, the tank has been chocked with
wood blocks or tires.
EXCAVATION
When no anchoring is required, the site has been
excavated deep enough to enable 1 foot of clean
sand or gravel to act as bedding material between
native soil and tank.
Burial depths meet minimum code requirements
(such as NFPA 30).
TESTING
The tank has been air-tested at 5 psig ( kPa) while
applying soap solution onto weld seams and
fittings to check or leaks.
OR
on a double wall tank, a vacuum test has been
performed in accordance with the fabricator’s
instructions.
All local and state testing requirements have
been performed.
ANCHORING
Not applicable to this site.
Deadman anchors used.
Concrete pad.
Soil and pavement overburden will hold down tank
(reference PEI/RP 100).
ACT-100®Label No.
Date:
CHECK( )
When anchoring with a concrete hold down pad,
a minimum 6 inch (152.4 mm) layer of bedding
material over the concrete pad dimensions to
separate tank from pad.
When deadman anchors or hold down pads are used,
hold down straps have been separated from the tank
by an inert insulating dielectric material at least
1 inch (25.4 mm) wider than the steel hold
down straps.
Tank is electrically isolated from the hold
down strap.
BACKFILL
Homogenous backfill consisting of clean sand,
pea gravel, #8 crushed stone or natural earthen
material has been used.
Backfill has been placed along sides of tank to ensure
full support along the tank’s bottom quadrant.
Backfill is the same material as bedding
PIPE CONNECTIONS
Nonconductive piping used.
Metallic piping used.
Dielectric bushings or flanges installed.
Signature and Title of Installing Foreman and/or Project Engineer
Installing Contractor