VACONODOME

INSTALLATION MANUAL

Issue: 12/2013

VACONO ALUMINIUM COVERS GMBH

Friedrichstrasse 50
79618 Rheinfelden
GERMANY

Tel +49 7623 717 86 0

Fax +49 7623 717 86 71

Email: vacono@vacono.com
Website: www.vacono.com

1
1. Introduction

VACONO is a family owned company located at South Germany close to Switzerland. The
company was founded in 1976 as a business unit of a big Swiss Aluminium company.
VACONO has more than 35 years of experience in Aluminium design and installation.

About 500 DOMES have been produced and installed all over the world in 100 countries.
The VACONO DOME can carry extreme snow loads in the mountains as well as heavy wind
loads of hurricanes or typhoons.

All products are engineered and produced in Germany. VACONO is present in 40 courtiers.

The VACONODOME parts are pre-fabricated in Rheinfelden and delivered ready for
assembly, complete with all necessary erection plans and instructions. All items are
individually numbered for easy identification (see overview drawing).

2
2. Erection Tools and Lifting equipment

2.1. Tool list for a team of 2 workers

The following list contains required standard tools. Depending on DOME structure and
DOME accessories may be further tools are required. This has to be checked in advance.

Required Tools per team

1 electric drill
1 pistol for silicon cartridges 310 ml (professional)
2 spanner set of wrench sizes 17, 19, 32 mm including 3/8" for EJOT screws or
2 impact screw driver for wrenches of 17 und 32 mm and 3/8"
1 cable drum 25 m with four plug sockets, 220 V
1 extension cable 25 m with three plug sockets, 220 V
1 tape measure 5 m
1 hand metal cutting scissor
1 electrical wood saw
1 bruss wire brush
1 spatula
1 box of paper towels
1 hammer (1 kg)
1 rubber mallet (1 kg)
2 pin wrench 9,5-10 mm
2 rivet guns for POP-Rivets 4.8 mm
1 Torque wrench (working range to 120 Nm)

Required Tools per DOME

1 electric angle grinder for aluminium (125 x 1 mm discs) per DOME
1 tape measure 50 m per DOME
1 air compressor (7-8 bar) per DOME

Special Tools for Lock bolt Assembly

1 Lock Bolt installation tool per team

Tripod Aluminium
Load capacity min. 2,5 to
lifting height min. 3,5 m
Weight 70 kg

Chain hoist
Load capacity min. 2,5 to
(available for purchase through VACONO)

3
2.2. Lifting equipment (if required)

Suspension ropes (if required acc. lifting plan)

The ropes for suspension have to be selected according to the specification of the
individual lifting plan. Standards are as follows:

 Grip hoist, load capacity max. 1,5 to).

Suspension ropes acc. lifting plan

Lifting device (as specified in lifting plan)

For DOME from inside a tank lifting devices and grip hoists are used. Following
components are required:

 Grip hoist, load capacity max. 3,2 to

 Lifting devices (fabrication drawings or purchase through VACONO)

4
3. Pre-Assembly Instructions

3.1. Inventory
As soon as all the material has delivered to site the completeness has to be checked
according to the packing list and parts have to be visually checked for damage. In case of
missing or damaged parts VACONO has to be informed immediately.

3.2. Material Storage & Handling

Panels are packed in transportation frames or wooden crates. Frames can be off loaded
by using sling for crane lifting. Wooden crates to be handled by forklift or cranes. Panels
have to be stored in upright position to prevent moisture accumulation. In order to avoid
water damage all the panels have to stored on dry area or to be covered with a tarpaulin.
Struts and clamp bars are bundled. All other components like supports, gusset, hub
covers and other small parts and materials are packed on pallets or wooden boxes.

The customer has to take care that the DOME material is stored accordingly.

3.3. Instruction Supervisor

The VACONO supervisor will instruct the team about prior to start of DOME installation.
After the instruction each team member has to sign a certificate about the successful
participation at VACONO instruction.

HOLD POINT => Certificate of participation at VACONO´s supervisor instruction

Usually the VACONO supervisor acts as a installation consultant. He is not responsible

for the execution of the work. He will nevertheless, within his possibilities, point out
deviations from the standard erection procedure to the responsible representative of the
customer to allow a good installation result

3.4. Welding Tension Ring & Stiffener

Preparation of tank rim shall follow details of VACONO GA drawing.
Welding work on topTension ring and stiffeners have to be completely installed prior to
start of DOME installation.

HOLD POINT => Quality Check position of tension ring versus VACONO design prior
to DOME installation release

3.5. Sandblasting
Sandblasting at the site where DOME is installed should be finished prior to start of
installation or only established after completion of DOME installation.

Sandblasting while DOME installation should be avoided since water tightness of gaskets
can be affected by the grit. Surfaces have to be kept clean prior to assembly of panels
and gaskets.

HOLD POINT => No Sandblasting Works while DOME installation

3.6. Fixed anchor point (as per EN795 A)

a) The fixed anchor point is used to ensure the safety of people having to go on the
dome for assembly or maintenance work. A fixed anchor point is provided for the
fastening of a maximum of 6 people.

5
b) Caution: any user must have the necessary physical fitness enabling him to use the
anchor point in a normal situation and to use it in an emergency situation.
c) Caution: only people trained in the use of the system and with the required
experience are authorised to use it.
d) Caution: an emergency plan must be drawn up with provision for all such emergency
situations as may arise in the course of work.
e) Caution: it is forbidden to undertake any modifications or additions without the prior
agreement of the manufacturer. All repair work must strictly comply with the
procedures authorised by the manufacturer.
f) Caution: the equipment must be used only for the purpose for which it is intended.
g) The fixed anchor point must be used only when it is used as shown in the diagram.

h) Caution: if more than two snap hooks are connected to the fixed anchor point, they
can interfere with each other. No more than two snap hooks should therefore be
connected to the anchor point.
i) Before use, make a visual inspection to ensure that there are no cracks and no
distortions
j) The upper pin must be positioned in place as shown. If not, it must be reconditioned
before any further use.
k) Caution: immediately stop using the anchor point:
 If there are any doubts about the safety of the equipment
 If the equipment has been strained by a fall
 If the fixed anchor point has been distorted by a fall.
Any distorted fixed anchor point must be replaced.
After any replacement, a fixed anchor point can only be used once it has been
properly inspected and given written approval by an authorised person.
l) As illustrated in the diagram, the fixed anchor point must be firmly connected to a
bearing structure of the dome.
m) Before any use is made of a fixed anchor point, the possible fall area must be cleared
to prevent hitting the ground or any other obstacle in the event of a fall
n) During assembly work, make sure that all sharp edges are properly neutralised.

Maintenance
The fixed anchor points are maintenance-free. A visual inspection every year is all that is
required (see Periodic inspection).

Periodic inspection
a) Caution: a periodic inspection is required to ensure the efficacy and safety of a fixed
anchor point.
b) A visual inspection must be made at least every 12 months.
c) Caution: the inspection must be carried out by an authorised person trained by the
manufacturer.

6
4.1) Standard Drawings for Installation

General Installation Guidelines for VACONODOME

These General Installation Guidelines provide an overview of important information which
are neccessary for a successful installation of VACONODOMES. It is mandatory that the
guidelines are being instructed to anyone who is directly involved in installation of
VACONODOMES.
Vaconos standard drawing set consists of four standard type drawings which will be provided
along with a VACONODOME.
? General Arrangement Drawing (GAD)
Main working drawing for engineering of
Vacono & Client. The approval of this drawing
is mandatory for the generation of the
Accessory & Assembly Drawing.

? Sectional Drawing Assembly

The main installation drawing to be used for
the structural & sheet assembly. Numbering
system on assembly drawing is being
explained within point 2) of general
installation guidelines.

? Sectional Drawing Accessories

provides a detailed view of the accessories to
be installed on the VACONODOME.

? Lifting Plan
the guideline which must be followed for
lifting VACONODOME on tank.

7
4.2) Numbering system of material in accordance with Sectional Assembly
Drawing
General Installation Guidelines for VACONODOME
These General Installation Guidelines provide an overview of important information which
are neccessary for a successful installation of VACONODOMES. It is mandatory that the
guidelines are being instructed to anyone who is directly involved in installation of
VACONODOMES.

Sectional Drawing Assembly (Numbering)

For simple installation beams, clamp bars,

?
sheets and gussets have a numbering system
which is logically arranged ascending from the
center to the rim.

Beams - The center beams (“star”) will always

?
have the number 1 and ascend to the rim in
odd numbers (1, 3, 5, 7,...). Further beams are
marked on one side with an ‘A’ to mount them
in the right direction.
A label on the beams is showing the order,
order pos. and beam number (e.g. 1083081 37
Order 601083: Order pos: 081, beam # 37)

Clamp bars - are always numbered (not on

?
drawing) with even numbers one number
higher than the beam it needs to be installed
on (e.g. clamp bar #2 needs to be mounted on
beam #1, clamp bar #12 on beam #11, etc.).
Clamp bars do not have specific direction they
need to be installed in.

Sheets (incl. rim sheets) - are consecutively

?
numbered to the beams in even and odd
numbers. (e.g. 70, 71, 72, etc.)

Gusset plates - are consecutively numbered

?
to the sheets in even and odd numbers. (e.g.
120, 121, 122, etc.)

Further the gusset plates are engraved with

the position of the beam to be mounted on the
special location as well as the order number in
combination with the gusset pos.
(e.g. 1286020026; Order: 601286, Order- Pos:
020, Gusset Plate # 026)

Hub covers - are not numbered and will only

?
occur in two sizes (450mm and 390mm) and
can be mounted on any same sized gusset
plate

Rim elements (except rim sheets) - are not

?
numbered as usually identical

8
4.3) Connecting Procedure for Dome Structure

General Installation Guidelines for VACONODOME

These General Installation Guidelines provide an overview of important information which
are neccessary for a successful installation of VACONODOMES. It is mandatory that the
guidelines are being instructed to anyone who is directly involved in installation of
VACONODOMES.

There are two typical of connections which can be

used to install VACONODOMES. There are Only fasten connections of one
common bolts and nuts and the lock bolt system ring permanently after the next
available. Independently from what system has ring has been closed!! (See
been chosen one rule applies for both: Assembly of Dome structure)

Connecting using nuts & bolts

When connecting the gusset plates with the

beams via nuts & bolts only hand tighten bolts
when “temporarily” closing a ring of the
VACONDOME. When the next ring has been
closed (see Assembly of Dome structure)
permanently tighten as per the below torque table:
bolted connection

Bolt Type Bolt Quality Thread Torque

Mk [Nm]
Galvanised Steel 10.9 M 10 x 1.5 72
10.9 M 16 x 2,0 310
Stainless Steel A2-70 M 10 x 1.5 45-50
A2-70 M 16 x 2,0 121

Connecting using lock bolt system

When connecting the gusset plates with the beams via lock bolt system use installation bolts
when “temporarily” tighten and insert lock bolts for permanent tightening as per procedure below:

1) Bolt placed into prepared hole - Collar placed over bolt

2) Tool is placed over the fastener pintail and activated

? Bolt head pulled against material
? Anvil pushes collar against joint
? Initial clamp generated

3) Tool swages collar, increasing clamp

4) Pintail breaks, installation complete

© Alcoa Fastening Systems

Perform bolting check after permanently tighten connection!!

9
4.4) Typical Assembly of Dome structure

General remarks for Assembly

The Dome structure is the core element of the VACONODOME and crucial for the mechanical
integrity. Therefore it is mandatory to install the beams without any tension to ensure the easy
installation of following rings as well as the smooth sheet placement in the further steps. When
the structure has been installed tension free, a perfect fit for the clamp bars can be ensured.

? If rings do not close easily, level structure with tripods and do NOT USE CHAIN HOISTS for contraction of Dome
structure
? Read connection procedure before commencing the installation

1
Place one
? Tripod in the center of the tank
Connect the first required beams (6-7 pcs. with the lowest
?
beam pos. #1) with the center gusset hub as per connecting
procedure
Place the “star” in the middle of the tank and align as per GA
?
drawing (mind the offset from Tank degree to Dome degree)

2 3 4

Place required gusset plates and

? Connect required gusset plates ?
? Connect required gusset plates
beams according to GA drawing and beams according to GA and beams according to GA
and connect as per connecting drawing as per connecting drawing as per connecting
procedure hand tight only procedure hand tight only procedure hand tight only
Permanently tighten the second
?
to last ring after last ring has been
closed and hand tightened as per
connection procedure

5 6
Place tripod as per lifting
? Continue
? the Dome
plan and lift to a level that installation as per Steps 4
next ring can be installed & 5 until last ring has
without touching the been completed and
floor follow guide line for lifting.

Connect required gusset

?
plates and beams
according to GA drawing
as per connecting

General Comments:

10
4.5) Pre-Assembly Instructions for sheet installation

General Installation Guidelines for VACONODOME

These General Installation Guidelines provide an overview of important information which
are neccessary for a successful installation of VACONODOMES. It is mandatory that the
guidelines are being instructed to anyone who is directly involved in installation of
VACONODOMES.

Sheets are the hull of the VACONODOMES and together with the clamp bars and gusset hubs have the
function of weather sealing the Domes. It is of a great importance to be accurate with the sheet installation
to maximize the effective erection. Here again it should be taken care that sheets should be installed
tension free (flat placement without creasing) to ensure a perfect fit of the clamp bars. Therefore the sheet
installation should only commence , after the 3rd ring is closed easily as then the first ring is tension free.

The clamp bars are installed to hold down the sheets and seal the sheet-to-beam-connection. The surface
and the screw channel should always be clean of debris, dust or similar as it would handicap the sealing
function of the clamp bar. Therefore all sand blasting works are strictly not permitted during Dome
installation on site to minimize the risk of blasting dust trapped underneath the gaskets.

A perfect result is to be expected when the sheet is placed tension free, the clamp bar on a clean surface
and tightened as per below instructions.

Clamp bar fixing instructions

Use one gusset hub temporarily to align the clamp bars. Mount
?
clamp bars as shown in the picture (right). After mounting remove
temporarily placed gusset hub for later silicone works.
Always tighten EJOT screws from the outside to the inside (or left
?
to right) without visible deformation of screw gasket
Knock down the clamp bars with a rubber mallet
?
Tighten EJOT screws with 12-15Nm (9-11 ft lb)
?
Beams must be clean and free of any debris before placing clamp
?
bars!
NEVER tighten screws from both sides
?
NEVER USE EJOT SCREWS FOR FIXING OF TEMPORARILY
?
PLACED CLAMP BARS

Clamp bar field repair instructions

To ensure perfect weather sealing at all times the following instructions need to be followed when measures
needed to be taken which are not compliant with the fixing instructions.

If tightened EJOT screw has to be loosen (for any given reason) the same must be replaced and the
?
clamp bar must be rotated by 180° and refitted
If a EJOT screw has broken off it needs to be carefully removed and the above measures to be
?
performed
Clamp bars can only be rotated once. If a second rotation would be necessary because of above
?
situations, new holes need to be drilled in the clamp bar and the initial ones caulked
NEVER USE EJOT SCREWS FOR FIXING OF TEMPORARILY PLACED CLAMP BARS
?

Special sheet placement for lifting points

Some sheets need to be temporarily left out
depending on lifting situation. For detail please see
chapter 5

11
4.6) Typical Assembly of Dome sheets for 1st Ring

Read Pre-Assembly Instructions

for sheet installation

Only start sheet installation after

3rd Ring has been closed

Never walk on sheets until all clamp

bars of respective sheet have been
permanently tightened

1 2
Insert first
? two Insert diagonal
?
sheets clamp bar between
sheet 1 and sheet 2
Install
? Circular whilst fixing as per
clamp bars tempo- clamp bar fixing
rarily as shown and instruction
knock down with
rubber mallet.
DO NOT USE ANY
?
EJOT SCREWS

3 4
Insert third sheet
? Insert diagonal
?
clamp bar between
Install
? Circular sheet 2 and sheet 3
clamp bar tempo- whilst fixing as per
rarily as shown and clamp bar fixing
knock down with instruction
rubber mallet.
DO NOT USE ANY
?
EJOT SCREWS

5 6
Insert fourth sheet
? Continue the above
?
steps until first ring
Install
? Circular has been completely
clamp bar tempo- covered with sheets
rarily as shown and and all diagonal
knock down with clamp bars are fixed
rubber mallet. as per clamp bar
DO NOT USE ANY
? fixing instructions.
EJOT SCREWS

General Comments: To increase work efficiency all sheets of

a ring can be placed followed by tightening clamp bars as
above or use two teams of which one does sheet placement

12
4.7) Typical Assembly of Dome sheets for 2nd till last Ring

Read Pre-Assembly Instructions

for sheet installation

Only start sheet installation after

3rd Ring has been closed

Never walk on sheets until all clamp

bars of respective sheet have been
permanently tightened

1 2
Remove all
? Insert 3 sheets as
?
temporarily placed shown (2 pointing to
circular clamp bars the inside, 1 pointing
of previous ring to the outside)
installed Insert circular clamp
?
bars temporarily as
shown and knock
down with rubber
mallet
DO NOT USE ANY
?
EJOT SCREWS

3 4
Insert diagonal
? Insert the next 2
?
clamp bars between sheets as shown (1
the sheets as shown pointing in, 1
whilst fixing as per pointing out)
clamp bar fixing Insert circular clamp
?
instruction (ONLY bars temporarily as
TIGHTEN THE shown and knock
TWO DIAGONAL down with rubber
CLAMP BARS mallet
PERMANENTLY) DO NOT USE ANY
?
EJOT SCREWS

5 6
Insert diagonal
? Continue the above
?
clamp bars between steps until the ring
the sheets as shown has been completely
whilst fixing as per covered with sheets
clamp bar fixing and all diagonal
instruction (ONLY clamp bars have
been installed
TIGHTEN THE
Then tighten circular
?
TWO DIAGONAL
clamp bars of
CLAMP BARS previous ring
PERMANENTLY) For next ring
?
continue with Step 1
?
General Comments: To increase work efficiency all sheets of Wear safety harness
a ring can be placed followed by tightening clamp bars as at heights and tie off
above or use two teams of which one does sheet placement
13
4.8) Pre-Lifting Instructions I

General Installation Guidelines for VACONODOME

These General Installation Guidelines provide an overview of important information which
are neccessary for a successful installation of VACONODOMES. It is mandatory that the
guidelines are being instructed to anyone who is directly involved in installation of
VACONODOMES.

Pre-tension of Dome
Horizontal (pretension) ropes for stabilization of DOME to be
fixed according to lifting plan (quantity and positions).

One end of the rope has to have a hook to be fixed with a

?
web sling at relevant gusset plate, the other end of rope with
no hook will be guided through a grip hoist which is fixed by
a web sling with the opposite gusset plate.
Rope to be tightened by grip hoist, controlling (flex of rope)
?
acc. lifting plan and approved with checking dimensions
mentioned on lifting plan
Tension of pre-tension ropes has to be controlled, approved
?
and released for lifting only by supervisor.
Web slings to be protected against damages by collision
?
with tank wall (e.g. cushioned through fire hose)

Special sheet placement for lifting points

For lifting, lifting lugs need to be attached to the gusset plate /
beam connections which requires to leave out sheets at
these areas. During all times it needs to be ensured that a
sheet is secured by at least 2 clamp bars at a time. Below are
the two possible lifting situations and an example of how the
sheets should be left out in this case.

Lifting with Crane

? When lifting the VACONODOME with a crane normally
the lifting points are located in one of the middle rings
(else refer to ‘Lifting with Grip hoists’ - method).
? As seen in the sketch the lifting point (red) lays between
two sheets pointing towards lifting point. These two
sheets can not be installed until lifting is completed.
? The other adjacent sheets need to be secured with at
least two clamp bars (green) as per clamp bar fixing
instruction permanently.

Lifting with Grip hoists

? When lifting the VACONODOME with grip hoists the
lifting points are located in the last ring
? As seen in the sketch the lifting point (red) lays between
three sheets pointing towards lifting point. These three
sheets can not be installed until lifting is completed.
? The adjacent sheets to one of the three sheets affected
by lifting need to be secured with at least two clamp
bars (green) as per clamp bar fixing instruction
permanently.
14
4.9) Pre-Lifting Instructions II

General Installation Guidelines for VACONODOME

These General Installation Guidelines provide an overview of important information which
are neccessary for a successful installation of VACONODOMES. It is mandatory that the
guidelines are being instructed to anyone who is directly involved in installation of
VACONODOMES.

All Lifting Activities strictly according

to Vacono Lifting Plan

Preparing lifting ropes for lifting with devices

mounted on top of the tank and grip hoists Lifting
Lifting devices to be fitted on top of tank at specific
?
Device Grip
locations as per lifting plan hoist

1) Vertical (lifting) ropes to be attached on one end with a

?
hook at the lifting device,

2) guided through a pulley, which is attached by hook and

web sling to DOME gusset plate
VACONODOME
3) and finally going over two rollers to the grip hoist which
is fixed at the lifting device.
Tank
103

15

123
2
4
8
8
1
1
4
8
2
2
2
2
3
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3957214860

Wall
Preparing lifting ropes for lifting with crane
Connect ropes via web slings to lifting points as per
? not to scale
lifting plan

Sole responsibilty
? for crane lifting is with crane operator Tension of pre-tension ropes
?
has to be controlled, approved
and released for lifting only by
supervisor
Preparing for lifting via tripods from floating roof Supervisor will control and
?
compare all data of lifting plan
Floating Deck level according to Lifting Plan
? and the correct assembly of
Approval of EFR load capacity of tripods
? ropes and lifting devices
Tripods to be checked because of height (lifting to rim
?
angle or tension ring !!) Tension
? ring need to be
checked against GAD

15
4.10) Typical Assembly of Dome -DOME Lifting

Vacono has to be consulted immediately if

Read Pre-Lifting Dome does not fit through tension ring or on
top of tension ring as per GAD. Work is to be
Instructions discontinued until further instructions by
Vacono engineering.

General Safety Regulation

Nobody will stay in the tank or below the DOME during lifting operation. All activities
?
have to be managed from outside the tank
Only one operator (supervisor) is responsible for lifting. The team has to follow strictly
?
his instructions

a) Lifting with crane (inside and outside the tank)

Crane operator and signalman (crane company or supervisor) have to be instructed and certified
?
according local crane operating regulations
A layout of crane operating company has to be available and be approved prior to Dome lifting
?
Sole responsibility is with crane operator
?
Attachment points according 4) Pre-Assembly Instructions for sheet installation, Lifting with crane
?
Mounting of Dome onto tank rim according "Support Mounting instructions"
?
Do not lift when wind speed exceeds Beaufort 3 (20 km/h or 10 kn)
?

Secure 50% of DOME supports (welding or bolting) prior to release DOME structure from
crane hook

b) Lifting with lifting devices (grip hoists manually activated)

One operator is responsible for coordination of entire lifting operation
?
Depending on DOME diameter separate DOME in appropriate segments and lifting teams
?
Select team leaders for the segment teams
?
Equip operator and team leaders with radios for giving lifting commands
?
Select appropriate number of strokes for on lifting unit according team and weather conditions
?
Coordinate horizontal level of each lifting device during lifting and avoid tilting of DOME
?
After passing tank rim install support bars and lower DOME according "Support Mounting
?
instructions”

Secure 50% of DOME supports (welding or bolting) prior to release DOME structure from
lifting devices

c) Lifting with lifting tripods from EFR

The DOME can be erected on the top of the steal floating roof in the same way as on the ground. The
tank has to be filled with water, so that the floating roof is going up.
? Installer has to approve EFR load capacity for tripod loads
? Install the DOME structure on EFR which has to be levelled according to Lifting Plan
? Ensure tripod attachment points that DOME can be lifted beyond the tank rim and support bars can
easily be fixed
? Lower DOME down to tank rim and fix supports according "Support Mounting instructions”

Secure 50% of DOME supports (welding or bolting) prior to loosen DOME structure from
tripods
General Comments: Wear safety harness at
heights and tie off when
working over 2m / 6ft
16
4.11) Typical Assembly of Dome -DOME Lifting (Mounting of Supports1/2)

Preparations
When a DOME has been lifted above tank rim following measures must been taken:

?Remove erection half gusset plates and replace with regular ones (if applicable)
?Install support arms on all accessible positions
?If tension ropes have been used, these have to remain in place until every 2nd of the
supports have been secured to the tank.

a) Mounting of Fixed Supports

1) Attach the steel support to the accessible support arms using the Aluminum bolt provided and
secure it with the split pins.

Lower the DOME with still with suspended ropes on to the steel tension ring while positioning the
DOME supports in the middle of the tension ring and landing the DOME stress less on the supports
brackets.

As soon as the supports are positioned correctly acc. the VACONO GA drawing the support brackets
can be welded to the tension ring.

Supervisor to check correct landing points of DOME supports

at the tension ring before welding.

When accessible supports have been welded and therefore the DOME will be secured to the tension
ring the suspension ropes can be released. After the removal of suspension ropes and the
installation of support arms and support brackets the welding of remaining supports to the tension
will take place.

In case that some support brackets will overhang more than 20 mm the tension ring has not been
positioned according VACONO GA and appropriate measures like additional stiffeners have to
welded below the support according customers requirements and approved by structural
engineering.

17
4.12) Typical Assembly of Dome -DOME Lifting (Mounting of Supports1/2)

Preparations
When a DOME has been lifted above tank rim following measures must been taken:

?Remove erection half gusset plates and replace with regular ones (if applicable)
?Install support arms on all accessible positions
?If tension ropes have been used, these have to remain in place until every 2nd of the
supports have been secured to the tank.

b) Mounting of Sliding Supports

Secure all support brackets to the slide plates

1) Drop the bolts with washers above the slide plates ensuring that white Teflon washer is under steel
washer (see details below )

2) Tighten square nut all the way to the bolt shoulder

3) Secure support brackets to slide plates with washers and nuts (finger tight only) and ensure square
nut sits inside the bracket slots. Position and fix the bracket in the middle of the slotted hole.

Landing and mounting of Dome on supports

a) Lift DOME with DOME Support Brackets attached

b) Lower and align the DOME on to top of tank.

c) Lower the DOME with brackets to the rim angle.

d) Secure first the support brackets at 0° and the opposite support bracket at 180° to the tank shell by
drilling holes or welding the brackets to the tank wall.

e) Continue securing each brackets support as described in g).

f) Tighten all nuts of the connection DOME Support Bracket / tank shell with a torque of F = 120 Nm
(SS M16).

g) Ensure again that the bolts in the slot are only finger tighten and the shoe plate may still "slide in the
slots".

h) Tighten lower nuts (i) of the DOME Support Brackets with a torque of F = 120 Nm (SS M16)

18
4.11) Typical Assembly of Dome - Hub Cover Installation and
sealing works
Preparations
Assembly of hub covers takes place only after the
DOME will be fixed on to the tank

Grooves of clamp bars, panels and gusset plates

?
have to be clean and dry
Gasket of clamp bars to be cut to same length as
?
clamp bars

After the sheets and clamp bars, the hub covers finish off the weather sealing of the VACONODOMES. As
the highest elevated part on the Dome structure (apart from the accessories) it is the most exposed part of
the Dome structure to wind and water. Therefore here again it needs to be taken extra care that the below
instructions are followed.

1) Silicone sealing

Apply a silicone seam along end of panels and gusset

?
plate.
?
Grooves of clamp bars to be filled about 100 mm (4")
?
with silicone.
Fill all the holes around gusset plate completely with
?
silicone.
The gasket to be fixed onto the gusset hub as shown in
?
detail below.

Never use Silicone below 5º Celcius

(41º Fahrenheit)

Visual check hub cover installation

2) Hub Cover Installation
Fix EPDM gasket as per detail above before assembly
?
of hub cover
Center hub cover over gusset plate
?
Tighten center bolt of hub cover without deforming hub
?
cover

After fixing of hub cover apply a small seam of silicone

?
above the end of clamp bar along the hub cover gasket

Apply a small seam of silicone along the clamp bar end

?
(100 mm (4") left and right side of clamp bar).

19
4. Installation of Accessories

4.1. Manholes
After positioning the manhole a hole is cut in the DOME sheet. The manhole is the bolted at
equal points to the DOME sheet. The same procedure applies for the centre vent.

4.2. Centre Vents

The bird screen situated underneath the cover plate should be cleaned of debris through the
use of hand brush every one to two years to ensure that there is no clogging of the air flow.

4.3. Walkways
Walkways on the DOME have to be installed according to the individual installation manual
and drawings which will be attached to the documentation.

In case that Anti Skid Pads will be adhesive bonded to the DOME sheets, i.e. for the
walkway or for the centre platform the following installation manual has to be considered:

Application of Anti-Slip Tapes on metal surfaces

a) State of surface
It is strictly recommended that the bonding will take place in a dust-free environment. In
addition, the ground must be clean, dry and uniform. Ideally, the bonding temperature should
be between 18-20°C (but not below 10°C). Before bonding, the metal surface must be at
room ambient temperature minimum (at least 1 hour prior). For this purpose, please use a
hot-air dryer if necessary.

b) Preparation of the surface

Please clean the surface with 40/60 alcohol/water-ratio (e.g. Isopropanol) and a dust-free
disposable cloth. Moreover, please use a scratch-free cleaning pad lager fouling. Please do
not touch the bonding surface after cleaning.

20
c) Bonding of anti-slip coverings
Anti-slip coverings can be trimmed accordingly. Please do not touch the adhesive surface of
the anti-slip tapes. The protective paper of the anti-slip coverings can be removed manually.
Please fix the anti-slip tapes as requested and remove approx. 20-30 cm of the liner. Then
please press on the anti-slip tapes on the surface. Important: The edges and endings must
be pressed on accurately. For this purpose, it is recommended to use a hard rubber role.
Instruction: Never bond over splices!

4.4. Negotiation Devices

The assembly procedure of the negotiation devices corresponds with that of the central
exhaust as well as those of the manholes. However this negotiation device must be aligned
and can only be fitted after the sheet is installed.

4.5. Suspension Supports for the Hanging DECK and the

Anti-Rotation System

21
5. Water testing

API 650 G.10.1 LEAK TESTING

G.10.1.1 After completion, the roof seams shall be leak tested by spraying the outside of the
seams with water from a hose with a minimum static head pressure 350 kPa (50 lbf/in.2)
gauge at the nozzle. Because of possible corrosive effects, consideration shall be given to
the quality of the water used and the duration of the test. Potable water shall be used unless
otherwise specified. The water shall not be sprayed directly on roof vents. Any water on the
inside of the roof shall constitute evidence of leakage.

Since this description can be interpreted in different ways VACONO recommends in addition
to the items of API 650 G 10.1 following best practice procedure:

Artificial water test

 Use a water hose of 3 to 4" diameter with an nozzle adjustable for water spray and
water jet. Ideally there should be a water tap to regulate the amount of water and to
close and open the water spray
 Place two workers onto the centre of the DOME, one for guiding water jet, one for
carrying the hose.
 Select water pressure that all the surface from DOME centre to DOME flashing can
be covered by the water spray and a natural rain can be simulated.
 Spray first a segment of 90° moving slowly the water spray from left to right side ill
360° will finally be covered.
 The water test will last 15 min.
 Go inside the tank to monitor the DOME roof for detection of eventual leakages.
 Mark the leaks in GA drawing for later repair measures.

 Repair measures
 As long as DOME will be installed strictly according instructions of VACONO´s
supervisor and the VACONO installation manual the DOME will have Zero leakage at
first water test.
 Leaks are mainly caused by non incorrect installation procedure.

 Main reasons for leaks can be:

o gusset covers
o clamp bars
o tension in sheets

Interpretation of results
 Depending on local climate the existence of a few drops during water test has also to
be taken in consideration with moisture of condensation. Therefore we suggest to
interpret the result as follows.
 One leak is existing when a leakage rate of about 6 and more drops per minute will
occur and appropriate measures acc. GLG have to be taken.
 As soon as a DOME has been optimised to Zero leakage further walking on panels
has to be avoided.

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