Attach 12 - Tower 808 Inspection Report (90808).pdf

Hurlburt Field, FL Tank No. 90808 Tank Inspection Report Project No.:49-060

Tank Name: 90808 Tank Type: Elevated Location: Hurlburt AFB Tank Capacity: 250,000 gallons State: FL Type of Construction: Steel Built By: Unknown Location:

Year Built: 1991 Inspected By:

Inspection Date: 2/22/19

GENERAL SUMMARY

Overall the tank is in fair condition with corrosion at most sharp edges and scattered throughout the tank surface, particularly on rod connections, ladders and floor of balcony. Coating system is beginning to show signs of failure with cracking and lifting of the multi-layer coatings throughout the tank surface.

RECOMMENDATIONS

Blast and repaint entirety of tank within next two years to prevent steel loss and protect long term integrity of the tank

Enclose electrical and control panels in weatherproof enclosure at next repaint

Re-install safety cable on primary ladder with correct alignment and tension after next repaint.

Replace exterior ladder or solid seal weld sections that are currently bolted together. Ladder appears to be salvageable at this time, but corrosion at junction of rungs and sides need to be corrected before steel loss requires replacement.

Reattach or replace obstruction lighting on top of tank. Lights are currently working but are not properly attached to roof of tank.

Replace heavily corroded ladder brackets of roof ladder prior to repaint.

STANDARDS

The inspection of the tank was performed with the tank nearly full and no cleaning was performed. The inspection consisted of a visual observation of the tank’s interior (as feasible with water present) and exterior components and coating system. Interior and exterior assessment was documented using digital still photography, representative samples of which are included in the Appendix of this report.

CONDITION OBSERVATIONS

Conditions noted in this report are documented in the following pages and supported by color photographs in the Appendix. Condition ratings used to describe field findings are defined as follows:

Excellent No deficiencies noted.

Good Minor deficiencies noted. Structure is functioning as designed.

Fair Major deficiencies noted. Structure is in need of repair (or replacement) to continue functioning as designed.

Poor Repair or replacement required immediately. Item no longer functioning as designed

CONTAMINATION, HEALTH & SAFETY REPORT

Contamination & Health Overall Condition: Excellent

Overflow pipe is equipped with screen, gasket and flapper to prevent access for insects

All manways and hatches fit properly and were closed Roof vent is properly screened to prevent access for insects

Facility Safety Compliance Overall Condition: Good

Tank is located inside locked, fenced area at secure military site All ladders and safety climb in good condition, but require some repairs and coating replacement within next 1-2 years to avoid replacement Unable to determine if proper safety grid is over riser entrance at base of bowl to prevent falls due to presence of water Has 2nd hatch on side of bowl for safety/access during painting projects

INTERIOR RESERVOIR INSPECTION REPORT

Interior Reservoir Roof Overall Condition: Fair

Most of ceiling coating in fair condition Heavy corrosion forming along thick, rough weld seams in ceiling Undetermined if cathodic protection system is working

Interior Reservoir Walls Overall Condition: Fair

Coating on walls in area of water surface showing consistent corrosion and coating failure

Coating on walls throughout showing signs of cracking and beginning to release from steel walls

Corrosion is evident on areas of walls below the water surface

Interior Reservoir Floor Overall Condition: Undetermined

Sediment and corrosion can be seen on floor of bowl, but complete inspection not possible without tank drained.

Interior Reservoir Plumbing Components Overall Condition: Good

Overflow pipe assembly is in good condition with corrosion along piping from water line up. Note: corrosion line on walls and overflow pipe indicate that tank is never completely filling, indicating need for adjustment in controls for filling of the tank.

Visible portion of fill pipe is in good condition with minimal corrosion in vicinity of water surface.

EXTERIOR RESERVOIR INSPECTION REPORT

Exterior Reservoir Roof Overall Condition: Fair

Coating on tank roof is in overall fair condition with scattered spots of minor corrosion, particularly along roof seams. Coating is beginning to crack and lift, which will expose steel to the elements if coating is allowed to continue to degrade.

Roof ladder in serviceable condition but brackets and weld connections require cleaning and recoating within next 1-2 years or will need to be replaced due to on-going metal loss.

Safety climb equipment on roof ladder is properly installed, including alignment and tension.

Roof vent is in good condition and is properly screened, but the tank/vent connection seam is showing minor to heavy corrosion around its perimeter.

Cathodic appear sealed but are corroding and staining top of tank Lip of primary hatch is corroded and should be rehabbed soon.

Exterior Reservoir Walls Overall Condition: Fair

Coating on exterior walls in fair condition with signs of corrosion and/or coating failures

Heavier corrosion along seams under tank belly, which is typical

Exterior Balcony Overall Condition: Fair

Coating on top of balcony in fair condition with signs of corrosion and/or coating failures

Balcony railing in good condition with no signs of metal loss at time of inspection

Exterior Riser and Leg Structures Overall Condition: Fair

Windage rods and support beams in fair condition with signs of corrosion and coating failures

Support beams in good condition with minor rust forming

Exterior Plumbing Structures Overall Condition: Good

Overflow pipe assembly in good condition and properly braced. Coating is starting to fail, as evidenced on remainder of tank, but piping is still salvageable.

Foundation Overall Condition: Good

Foundation of riser and legs in good condition with grout loss between base and foundation

Minor corrosion on anchor bolt nuts with some areas of heavier corrosion on base plates around bolts.

GENERAL TANK SECURITY

Security Overall Condition: Excellent

Tank is located inside locked, fenced area at secure military site Exterior ladder is protected by locked ladder guard

Cathodic Protection System

Type, size, material and # of anodes: Overall Condition: N/A

Present but condition unknown.

TABLE 1 - Coatings Schedule

Coating System Surface Prep

Prime6 (mils - DFT)

Product4

Intermediate #17 (mils - DFT)

Product4

Intermediate #2 (mils - DFT)

Product4

Final (mils - DFT)

Product4

Total System (mils - DFT) Min 5 - Max 5

OCS-4

(Modified)

SSPC-10 Zinc-Rich Primer

2.5 - 3.5

Series 91-H20 Hydro-Zinc

Epoxy 3.0-5.0

N140 - 1255 Pota-Pox Plus

Polyurethane

2.0 - 3.0

1075 Endura-Shield

Fluoropolymer Urethane

2.0 - 3.0

Series 700 HydroFlon

9.5 - 14.5

ICS-3

(Modified)

SSPC-10 (Immersion) Zinc-Rich Primer

2.5 - 3.5

Series 91-H20 Hydro-Zinc

100% Solids Epoxy2

25.0 - 35.0

Series FC22 Epoxoline

27.5 - 37.5 (42.5 - 52.5)3

Concrete SSPC-7 Acrylic Elastomeric

4.0 - 6.0

Series 156 Enviro-Crete

Acrylic Elastomeric

4.0 - 6.0

Series 156 Enviro-Crete

10.0

1 A stripe coat of epoxy shall be applied by brush to all weld seams, ladders, edges, etc., prior to receiving first intermediate coat on exterior surfaces and prior to the finish coat on interior surfaces.

2 All interior roof beams, sharp edges and other difficult to coat areas shall receive 35.0 – 45.0 mils of epoxy lining 3 Total Dry Film Thickness for roof beams, sharp edges and other difficult to coat areas 4 All products are as manufactured by Tnemec Company, Inc.

5 Mil thicknesses for individual coats shall not exceed manufacturer’s written recommendation.

6 An additional coat of zinc-rich primer shall be shop-applied to the replacement ladders and other replacement parts.

7An additional coat of Intermediate #1 shall be applied to the tank bowl exterior from the base of the balcony to the riser stem junction. Total System for this area shall be 12.5 to 17.5 (mils DFT)

Appendix

Photos

1- Tank ID

2 - Data Plate (Built 1991)

3-Riser hatch bolts heavily corroded

4-Sample tap piping properly insulated

5-Grout and coating failure at riser base

6-Sample tap properly insulated

7-Corrosion and coating failure at anchor bolt

8-Overflow cover face and screen corroding

9-Overflow flapper installed properly

10-Severe coating failure around sample tap penetration

11-Sample spot of coating crack

12-Coating failure at base of riser

13-Widespread cracking of coating with spots of breakthrough corrosion

14-Base of leg and tension rods

15-Coating cracked, lifted and unprotected steel corroding at base plate

16-Coating failure on tension rod brackets and bolts

17-Coating failure on base plate

18-Electrical conduits properly sealed

19-Ladder gate properly installed and locked upon arrival

20-Electrical and control boxes exposed to weather

21-Tank secured in locked fence

22-Coating on cross bracing beginning to fail and corrosion forming

23-Coating beginning to fail and separate on sharp edges on tension rod turnbuckles

24- Coating beginning to fail and separate on sharp edges on tension rod turnbuckles

25-Bolts on rods beginning to corrode

26-Closer view of turnbuckle corrosion

27-Widespread coating system cracking and lifting

28-Detail of cracking, lifting coating system. Bare steel to be exposed as coating begins to flake off.

29-Safety climb loose and out of alignment

30-Coating failures

31-Corroded, bolted ladder connection. Should be replaced or welded during repaint.

32-Bolted ladder connection

33-Ladder rungs corroding at connection point

34-Coating cracking and failing on ladder and ladder brackets

35-Ladder rung coating failure

36-Coating failure on uppermost windage rods and seams on belly of tank

37-Closer view of belly and rods. Rods appear to be salvageable at this time

38-Coating failure and corrosion at rod and beam connections

39-Coating failure on support rod

40-Corrosion on bolts at rod and beam connections

41-Close up of coating failure and corrosion at bolt connections

42-Corrosion forming on sharp edges on tank exterior

43-Mildew and widespread coating cracking

44-Ladder brace corroding will require replacement or welding repair

45-Ladder safety equipment mis-aligned but balcony opening is adequate

46-Toe clearance for ladder at balcony is adequate. Ladder is corroding but salvageable.

47-Coating on balcony floor cracking and corrosion forming. No apparent structural damage to date, but should be addressed in a timely fashion.

48-Balcony floor and railing coating failures. No cross bracings on railing.

49-Abnormally thick weld seam (should have been ground smooth after construction). Edges are beginning to corrode.

50-Corrosion and paint failures at exterior bowl weld seams

51-Thinning top coat of paint system

52-Coating on balcony floor cracking, blistering and failing. Exposing steel to corrosion formation.

53-Conduit brackets corroding and bleeding onto tank wall

54-Corrosion forming at weld seam of balcony toe kick.

55-Widespread coating failure and corrsion on balcony floor

56-Coating cracking and failing on stem of extra hatch on side of tank bowl (and bolts are corroding)

57-Corroded hatch cover, bolts and balcony floor

58-Corroded bolts, roof ladder braces and balcony floor

59-Coating cracking and failing on exterior of bowl

60-Old bracket connection corroding on side of roof ladder. Should be removed during repaint.

61-Coating failure and corrosion on bottom roof ladder brackets

62-Close up of coating system cracking down to bare metal. Corrosion forming as steel loses protection.

63-Heavy cracking around top of roof ladder from systemic coating failure on exterior of bowl. Cathodic protection bolts corroding also.

64-Heavy cracking of coating around and on roof ladder brackets.

65-Safety climb installed correctly on bowl ladder. Rungs of ladder exhibiting coating failures.

66-Exterior coating cracking and beginning to peel, allowing underlying steel to corrode

67-One obstruction light not secured to top of tank. Support poles for other lighting and roof in the vicinity of lights corroding.

68-Coating cracking and steel corroding on roof of tank

69-Ladder and hatch exhibiting coating failure and corrosion.

70-Coating cracking and peeling at junction of tank roof and vent

71-Corrosion forming at junction of roof and vent.

72-Heavy corrosion of roof ladder bracket.

73-Remnants of old bracket corroding. Should be removed at next repaint.

74-Cathodic protection cover corroding and staining top of tank.

75-Rooftop coating cracking, blistering and peeling

76-Exterior coating cracking and lifting

77-Interior corrosion at water line

78-Interior corrosion at weld seam above water line

79-View of inlet/outlet pipe through water (which is clear). Doesn't appear to be safety grid over pipe entrance, which creates a fall hazard during tank maintenance.

80-Interior of bowl side hatch and ladder descending into bowl. Both are showing signs of corrosion requiring recoating.

81-Corrosion at water level and along tank wall below water line. Dark area at bottom is staining and sediment.

82-Water is remaining several feet below overflow elevation in the tank with corrosion forming on walls and overflow piping at current water line.

83-Underside of balcony exhibiting coating failure, particularly along sharp edges

84-Underside of balcony at tank leg junction. Coating failing and peeling along thick, rough weld seams.

85-Corrosion on wind rods and bolted connections under belly of tank

86-Underside of balcony

87-Underside of balcony. Coating failing and peeling around weepholes in balcony floor.

88-Ladder rungs are 16" in width, which meets current OSHA code.