Facility Construction

Facility Construction

The building we had to work with was nothing but a 52'x30' clear span garage. It was perfect for us since it had to interior walls, dry wall or plumbing. This gave us the opportunity to wire, insulate and install everything we needed without having to rip out any walls.

Framing the tanks

Our tanks were built using lumber and plywood as our foundation. This gave us more flexablility to build the tanks exactly the size we needed.
Building the tanks was much more time consuming than anything else. Everything was custom built by hand and we were designing as we were building. This meant we had to anylize and re-anylize every piece of wood and screw before we could actually build anything. The first of the pair of systems probably took 3 times longer to make for this reason.

Plywood

When the basic framing was done the tanks were lined with high quality plywood. The tank walls were insulated to keep in as much heat as possible.

Painting the tanks

Painting turned out to be one of the most time consuming parts of the project. Wood does not mix very well with salt water so we needed to paint everything numerous times to make sure it would never rot. All the studs were painted before putting the plywood on to make sure there would be no humid air getting into the gaps. The shelving all has 8-10 coats of paint and the tanks themselves have 10-12 coats.

Epoxy

After finishing the tanks came the daunting task of making them waterproof. We did alot of research on different kinds of epoxies and ended up using a top of the line racing boat epoxy made by M.A.S. Epoxies.
We had no previous experience using epoxy so it was a slow process in the beginning. Getting the thickness and coloration right was somewhat of an artform and it took alot of trial and error work before the process was perfected.

Plumbing and filling

Finishing the tanks was pretty much the easiest part of the project. Each tank has 3 overflows which are used to create the surges. Once the water level reaches a certain height in the first tank it creates a spihon and discharges 40-50 gallons of water to the tank below it in a matter of seconds. That forces the next surge to fire and so on.

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Facility Construction

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