IFB#250 Add #1 Tank Inspection

Beulah Elevated Tank – May 2017 1

BEULAH TANK

500,000 Gallon Elevated Tank

Beulah Elevated Tank – May 2017 2

I. Introduction

On May 16, 2017, the Beulah Tank was taken out of service, cleaned, and a complete interior and exterior inspection was performed. Once the inspection was complete, the tank was disinfected in accordance with AWWA recommendations and put back into service soon after. The Beulah Tank was previously inspected in December 2014. The 2017 inspection was performed in order to determine the extent of changes in the condition of the tank. The following is an updated summary to reflect the findings of the 2017 inspection. Observations made during the 2014 inspection will remain unchanged if progression/worsening of the condition was not noticeable. Also included in the inspection report is a list of recommended rehabilitation work, a construction cost estimate, historical maintenance records, and a recommended maintenance ranking compared to other water storage tanks in the

Douglasville – Douglas County Water and Sewer Authority (DDCWSA) water system.

II. General

B. 500,000 gallon elevated tank

C. Welded steel construction

D. Located near the intersection of Burnt Hickory Road and Veterans Memorial

Highway.

E. Elevated torospherical bowl supported by 8 welded steel columns with tie rods

F. 60 inch diameter welded steel riser

G. Concrete pedestal foundations

III. Observations

A. Exterior Coating

The coating on the exterior of the tank is generally in good condition. Adhesion of all layers of the coating system, inter-coat and substrate, appeared to be good. The coating system has an average dry film thickness of 15 mils. Most of the exterior of the tank/support columns have a thin layer of mildew growth and the protective coatings were chalking

(deterioration of epoxy binder). A few minor areas of coating failure were observed (one of which appeared to be damage from a projectile). The balcony handrail is beginning to exhibit coating failure and minor corrosion.

B. Column Foundations and Anchor Bolts

All eight (8) of the tank column foundations were inspected. Concrete foundations appeared to be in good condition. The grout bearing pad (between column anchor plate and concrete foundation) on columns 3, 4, 5, 6, 7, and 8 was in poor condition. The grout in these locations was spalled and corrosion on the column anchor plate was beginning to occur.

Beulah Elevated Tank – May 2017 3

Corrosion was observed on exposed anchor bolts below the anchor plate on columns 4 and 6 due to spalled grout. Corrosion and minor rust bleed was noted on the tie rod turn buckles and where tie rods cross and are rubbing. The riser foundation had areas of spalled grout and corrosion at the interface of the anchor plate and grout bed. Minor coating cracking and corrosion was observed on the majority of the column and riser anchor bolts.

C. Interior Coating

The interior coating system was generally in good condition with some isolated areas of coating failure. Facial rust and rust bleed were present on the upper bowl plates and roof beams. There were approximately 20-25 areas of spot corrosion and coating system failure in the bottom section of the bowl and along the weld seams. Pitting was observed at some of the areas of corrosion. The depth of the observed pitting was minimal.

Approximately five (5) pits with exposed steel were coated with a 100% solids epoxy during the 2017 inspection. Previous metal pitting had been coated prior to the inspection and appeared to be in good condition. The 2014 inspection noted that additional coating had been applied to the weld seams and the bottom plates of the bowl. Adhesion of all layers of the coating system, inter-coat and substrate, appeared to be good. Coating thickness was tested resulting in an average thickness of 18.5 mils.

The interior of the riser exhibited small areas of coating failure and corrosion.

Barnacle corrosion was noted near the bottom of the riser.

D. Exterior Accessories

The tank is equipped with a column ladder and fixed bowl ladder. The column ladder extends through the tank balcony and appears to be structurally sound. Both the leg ladder and bowl ladder are equipped with a cable safety climb system; the bowl ladder safety climb system has recently been replaced. The column ladder has a lockable ladder shield.

The tank bowl balcony is 48-inches wide and has a 48-inch tall handrail. The balcony has drainage holes that prevent the majority of water from pooling on the balcony. Two (2)

SCADA antennas are mounted to the balcony handrail. Three additional Yagi antennas are mounted to the top of the tank vent. One (1) antenna mast is not currently used. According to DDCWSA, the radio SCADA antenna is not in service. A 24-inch flanged manway is located on the balcony to provide access to the bowl interior. This manway was not opened during the inspection.

The roof hatch is a 24-inch square opening with a hinged and lockable cover. Face rust was observed around the perimeter of the hatch. The tank vent is a hexagon vent with six

Beulah Elevated Tank – May 2017 4 vent screens. Face rust was noted on the vent screen covers and weld seams. The tank is not equipped with obstruction lighting.

The riser is equipped with a 24-inch diameter flanged manway. The manway appears to be in good condition with the exception of the corroded bolts. The manway is not hinged.

E. Interior Accessories

The tank bowl is equipped with two interior ladders (roof hatch and balcony manway); both of which have minor spot corrosion throughout their length. Only the roof hatch ladder is equipped with a cable safety climb system. A safety grate is installed at the top of the riser. The safety grate exhibited face rust on most of the steel members.

The tank riser has a 12-inch inlet-outlet pipe with deflector plate, an 8-inch drain line, and an 8-inch overflow pipe. The piping inside the riser appears to be in good condition.

The inlet outlet pipe is equipped with a removable silt stop assembly that extends 34 inches from the riser floor.

The overflow pipe extends up the wet riser and is supported from the riser wall at intervals along its length. The overflow pipe inside the bowl exhibited minor corrosion at its flanged connections.

F. Site

The tank site was clean and well maintained. The tank overflow/drain is routed off site and discharges into a manhole. The tank eventually drains to a swale on the West side of

Veterans Memorial Highway.

Site fencing is in good condition. The fence is topped with 3-strand barbed wire, and has a double leaf gate to provide access to the site. Trees and undergrowth, which were protruding through the tank site’s South fence, have been trimmed back. However, several trees/limbs still remain and are anticipated to continue protruding onto the site.

IV. Maintenance Priority

Based on observations described herein, and specifically based on the overall condition of the interior of the tank, the Beulah Tank has been assigned a 2, New Pitting, since the areas of spot corrosion are beginning to show signs of pitting. Even though there is new pitting, the areas are small and represent less than 1% of the entire interior tank structure.

V. Recommendations

Beulah Elevated Tank – May 2017 5

Rehabilitation recommendations include:

A. Exterior Surfaces

Overcoat existing tank with an epoxy prime coat and urethane finished coat.

Mechanically clean areas of spot corrosion prior to coating application.

Repair spalled grout at concrete foundations.

B. Interior Surfaces

Abrasive blast steel surfaces to a near white finish per SSPC-SP10 and recoat with a three coat epoxy system.

C. Accessories

Remove obsolete antenna mast from top of tank.

Install flap valve on drain/overflow pipe.

Arrange the drain and overflow piping configuration to maximize the benefit to DDCWSA.

Install sample tap on riser.

Install swing hinge for riser manway.

D. Site

Trim overgrowth back from fence.

VI. Historical Improvements, Repairs and Inspections

Item Date Year Constructed 1975

Rehabilitated (Exterior and Interior) 2000

Washout, cleaning and inspection 2014

Washout, cleaning and inspection 2017

Beulah Elevated Tank – May 2017 6

Figure 1 - Riser Manway

Figure 2 - SCADA Cabinet

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Figure 3 - Column No. 1 with Ladder

Figure 4 – Typical Column Foundation

Beulah Elevated Tank – May 2017 8

Figure 5 – Spalled/Cracked Grout (Typical at Tank Column No. 3,4,5,6,7 and 8)

Figure 6 – Mildew Growth on Column

Beulah Elevated Tank – May 2017 9

Figure 7 – Typical Anchor Bolt Connection

Figure 8 – Typical Tie Rod Turn Buckle

Beulah Elevated Tank – May 2017 10

Figure 9 – Below Riser Foundation: Inlet/Outlet, Overflow, and Drain Piping (Left to Right)

Figure 10 - Inlet/Outlet & Deflector

Beulah Elevated Tank – May 2017 11

Figure 11 – Riser Ladder and Overflow Pipe

Figure 12 – Spot Corrosion on Riser Interior

Beulah Elevated Tank – May 2017 12

Figure 13 - Column Ladder at Balcony

Figure 14: Mildew on Tank Balcony

Beulah Elevated Tank – May 2017 13

Figure 15: Drainage in Balcony Floor

Figure 16: Bowl Ladder and Safety Climb Cable

Beulah Elevated Tank – May 2017 14

Figure 17: Vent and Yagi Antenna Mount

Figure 18: Tank Vent

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Figure 19: Exterior Bowl Ladder and Bowl Roof Hatch

Figure 20: Roof Hatch, Balcony Manway Bowl Ladder, Roof Vent, Level Indicator System, and Balcony

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Figure 21: Roof Hatch

Figure 22: Interior Ladder to Balcony Manway

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Figure 23: Overflow Pipe and Interior Roof Plates

Figure 24: Cleanout of Tank Interior

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Figure 25: Riser Safety Grate

Figure 26: Spot Corrosion with New Pitting

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Figure 27: Spot Failure with Pitting

Figure 28: Typical Bowl Interior (After Cleanout)

Beulah Elevated Tank – May 2017 20

Figure 29: Spot Failure with Barnacle Corrosion

Figure 30: Drain/Overflow

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Figure 31: Site Fence

Figure 32: Tank Site (Typ)

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Figure 33: Valve/Vault Work in Progress

Figure 34: Overall Tank Site

Beulah Elevated Tank – May 2017 23

Figure 35: Tank Site

END OF REPORT

Beulah Elevated Tank – May 2017 24

THIS PAGE IS INTENTIONALLY LEFT BLANK

APPENDIX A

Construction Cost Estimate

Item No. Quantity Unit Description Unit Cost Total Cost

Exterior

1 19,600 SF Pressure Wash, Spot Prime and Overcoat 3.50$ 68,600$

Interior

1 10,000 SF Abrasive Blast and New Coating System 12.00$ 120,000$

Accessories

1 1 LS Remove Obsolete SCADA Radio Antenna 500.00$ 500$

1 1 LS Install Flap Valve on Drain Discharge 1,200.00$ 1,200$

1 1 LS Install Sample Tap on Riser 1,200.00$ 1,200$

1 1 LS Install Swing Hinge for Riser Manway 1,500.00$ 1,500$

Site

1 1 LS Trim Overgrowth from Fence $ 250.00 $ 250

Subtotal 193,250$

Bonds and Insurance (2.5%) 4,831$

Mobilization (5%) 9,663$

Construction Contingency (10%) 19,325$

SUBTOTAL 227,069$

Engineering and Inspection (15%) 34,060$

Inflation (5%) 11,353$

OPINION OF TOTAL COST 272,483$

BEULAH RECONDITIONING

ENGINEER'S OPINION OF PROBABLE CONSTRUCTION COSTS

APPENDIX B

Field Inspection Report

17038

5/16/2017

Sunny, 80's

Veterans Memorial Hwy and

Burnt Hickory Intersection

66.5'

Ht. to Bottom 123'

Ht. to Overflow 156'

Construction Welded Steel1975

Capacity

Contractor

Serial Number

Column 1: Access Ladder, Minor mildew growth, minor coating chipping (spot damage from possible projectile), overall good condition; minor rust bleed at tie rod connection;minor coating cracking corrosion on anchor bolts and minor alligator cracking at column midpoint.

Erected (Date)

TANK INSPECTION FIELD REPORT

ELEVATED WATER TANK

Weather:

Address:

NAMEPLATE INFORMATION

Water System:

Tank Name:

Press. System:

Type:

Datum:

Krebs Job No:

Date:

Diameter

N/A

Brown Steel Contractors, Inc.

DDCWSA

Beulah

Zone 1342

Elevated

1342.00'

500,000 Gallons

Safety System: Cable climbing system

Rung Spacing: 12" Ladder Width: 16"

SUPPORT COLUMN(S)

Number of Columns/Legs: 8

Coating Condition (Location and Millage): Coating Thickness: 8-23 mils, Avg. 15 mils; Intercoat adhesion is good;

Coating adhesion to steel substrate excellent. Good condition w/ only a few areas of failure (spot damage from possible projectile) and alligator cracking in a small area on the riser

Column 2: Slight mildew growth, overall good condition; minor coating cracking at anchor bolts.

Column 3: Spalled grout below base plate, slight mildew growth, overall good condition; minor coating cracking at anchor bolts.

Foundation/Base Plate/Anchor Bolt Condition

Column 4: Spalled grout below base plate, one anchor bolt exposed below base plate with corrosion present, minor coating cracking at 1 anchor bolt.

Column 5: Spalled grout below base plate, overall good condition; minor coating cracking at anchor bolts.

Column 6: Spalled grout below base plate, one anchor bolt exposed below base plate with corrosion present, minor coating cracking at 1 anchor bolt.

Tie Rod/Turnbuckle Condition: Minor mildew growth, some coating damage where the turnbuckle rods cross, overall in good condition.

Miscellaneous Comments: Additional security measures include ladder shield and bottom section of ladder removed

Column 8: Spalled grout below base plate, Spot corrosion on anchor bolts, overall good condition

Column 7: Minor coating chipping (spot damage from possible projectile), Slight mildew growth, overall good condition; minor coating cracking/corrosion on anchor bolts; minor spalling of grout.

Column Ladder

Ladder Location: Column 1, Comm. cables are attached to the ladder; some cables are sloppily attached

Balcony

Width: 48"

Positive Drainage: OK; additional openings added to balcony after original construction; mildew present

Handrail Height: 48"

Bowl Ladder

Bowl General Condition: Generally in good condition, minor alligator cracking, few areas of chipped top coat, areas of spot coating applied

BOWL, EXTERIOR

Riser Ladder

Safety System: None Ladder Width: 16"

Rung Spacing: 12"

Coating Condition (Location and Millage): Good condition w/ alligator cracking on exterior (small area), Isolated spots of barnacle corrosion and alligator cracking on interior steel; Top coat chipped in a few areas

Miscellaneous Comments: Corrosion on riser manway flange bolts

Opening Size: 24" diameter

Type (Hinged/Flanged): Flanged

RISER

Riser Type(Wet/Dry): Wet Riser Diameter: 60"

4" Raised Curb Surrounding Opening: Yes 2" Overhang on Hatch Cover: Yes

Roof Vent

Type: Hexagon Vent Insect Screening: Yes

Size: 30" Width

Fixed/Rotating: Modified to be fixed (welded)

Safety System: Cable

Rung Spacing: 12" Ladder Width: 16"

Roof Hatch

Size: 24" Square Hinged: Yes Lockable: Yes

Miscellaneous Appurtenances(Antennas, Safety Devices): Three Yagi antennas at vent and one antenna mast

(not used), Two communication antenna mounted to handrail

Coating Condition (Location and Millage): Good condition w/ coating exhibited a few minor issues with chips in the top coat and alligator cracking. Coating Thickness 8-23 mils, Avg. 16.5 mils; handrail is exhibitting coating failure and corrosion in areas. Good adhesion

Level Indicator Assembly

Type: Cable and Float Operational: No

Type: None Operational:

Obstruction Lighting

Riser Foundation/Base Plate/Anchor Bolt Condition: Spalled grout below base plate; Corrosion at interface of base plate and grout; minor corrosion/ coating cracking at anchor bolts

Riser Manway

Miscellaneous Comments: Communication cables attached to bowl ladder

Weir/Overflow Structure: Flared inlet

Condition: Good, some rust bleed at flanged connection locations

Interior Ladder

Safety System: Safety cable

Silt Stop Drain Assembly

Height: 34" Removable: Yes

Condition: Adequate, Equipped with 12" deflector plate

BOWL, INTERIOR

Inlet/Outlet Piping

Size: 12"

Condition: Acceptable

Bowl General Condition: Minor spot coating failure, two areas with exposed steel (coated with 100% solids system during inspection), some rust bleed from roof beams. Approximately 20-25 spot corrosion locations observed on the bowl. Interiror coating system generally appeared to be in good condition.

MISCELLANEOUS SITE CONDITIONS

Overflow/Drain Piping

Size: 8"

Flap Valve: Unknown (discharges inside MH) Discharge to: Swale across Verterans Memorial Hwy

Sample Tap: Yes

Coating Condition (Location and Millage): Good w/ only a few areas of failure - barnacle corrosion and exposed steel, both locations of exposed steel were located under the interior bowl ladder and were probably the result of overspray or excess coating drips. Intercoat adhesion is good, Coating adhesion to steel substrate excellent.

Coating Thickness 8-46 mils, Avg. 18.5

Metal Pitting (Location and Depth): Two areas with exposed steel and minimal pitting (coated during inspection), Evidence of past pitting which has been overcoated, appears to be isolated to bottom plate ring of bowl; Bottom plate ring, some weld seams, and spot coating systems appear to have been applied. Several areas of pitting were observed and filled with aquatapoxy (Point Repair Coating).

Miscellaneous Comments: Tank equipped with a balcony manway (24" diameter) and interior bowl ladder.

Rectifier Type:

Wiring Condition:

Rectifier Location

Enclosure Condition:

Rung Spacing: 12"

Mounting System: Welded at floor and roof

Ladder Width: 16"

Riser Opening Safety System: Yes, steel grating

Cathodic Protection

No. of Anodes: Anode Condition:

Overflow Piping

Size: 8", extends down inside riser, Adjacent to riser ladder making access an issue

Location of Samples Taken: None Taken - information from last rehab project available

Interior -

Exterior -

Site Grading/Drainage: Appears adequate

Access Road Condition: Gravel/grass, good condition

Miscellaneous Site Comments: Small site with major roads located along the north and west sides. Rehabilitation will require a draping system; Trees have been trimmed back from the the tank; however, some trees/limbs still growing over/through the site fence. Valve vault construction present at the time of inspection.

Fencing:

Height: 7' Type: Metal Security Wire: Yes

Condition: OK, Vegetation protruding through fence and bottom fabric pulled up in places

Gate Type: Double Leaf

COATING SAMPLES

APPENDIX C

Site Plan

SHEET TITLE

SHEET NO.

DATE

PROJECT NO.

SCALE

17037

BHM-ENGL-02 4:28:01 PM P:\bham\Douglasville\17037_WestBanksMill_BeulahTank\Drawings\17037-S1.dgn6/9/2017

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NO SCALE

MAY, 2017

WATER AND SEWER AUTHORITY

DOUGLASVILLE - DOUGLAS COUNTY

ELEVATED STORAGE TANK

BEULAH 500,000 GALLON

DOUGLASVILLE, GEORGIA

S1

SITE PLAN

NOTE: SKETCH PROVIDED BY DDCWSA.

A

A

OVERFLOW PIPING

TANK RISER

RISER

SECTION A-A

PIPING

OVERFLOW

PIPING

DRAIN

RISER

DRAIN PIPING

NEW VALVE ON DRAIN/OVERFLOW PIPING

APPENDIX D

Aerial Photo of Site

SHEET TITLE

SHEET NO.

DATE

PROJECT NO.

SCALE

AERIAL PHOTO

T1

17037

MAY 2017

BHM-ENGL-02 2:39:39 PM P:\bham\Douglasville\17037_WestBanksMill_BeulahTank\Drawings\17037_BeulahTank-T1.dgn6/5/2017

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, IN

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WATER AND SEWER AUTHORITY

DOUGLASVILLE-DOUGLAS COUNTY

ELEVATED STORAGE TANK

BEULAH 500,000 GALLON

DOUGLASVILLE, GEORGIA

NO SCALE