Application Procedure - Tank Bottam

LLOYD INSULATIONS M/s.
Thyssenkrupp Industrial GSFC – Sikka, Jamnagar

(INDIA) LTD Solutions (India) Pvt. Ltd, Sikka
Jamnagar
Doc No.LIIL/TKIS/INSUL/001
APPLICATION PROCEDURE FOR

BOTTOM INSULATION FOR AMMONIA STORAGE TANK
GUJARAT STATE FERTILIZERS &

OWNER:- CHEMICALS LTD - SIKKA
THYSSENKRUPP INDUSTRIAL
CLIENT:- SOLUTIONS (INDIA) PVT LTD
LLOYD INSULATIONS (INDIA)

CONTRACTOR:- LIMITED
Doc. No. LIIL/TKIS/INSUL/001
Sign:
Date
Name
Prepared By Approved by Reviewed By

Revision-00
LLOYD TKIS GSFC
Doc. No. LIIL/TKIS/INSUL/001 1

LLOYD INSULATIONS M/s. Thyssenkrupp Industrial GSFC – Sikka, Jamnagar
Jamnagar
Table of Contents
1 SCOPE OF WORK
2 DIMENSION OF PERLITE CONCRETE
3 REFERENCE DOCUMENTS
4 MATERIALS
5 MIX DESIGN
6 APPLICATION & POURING
7 REPORTS
8 PROCEDURE FOR TANK BOTTOM
9 INSPECTION AND TEST PLAN FORMAT
10 SITE ORGANIZATION CHART
11 QUALITY ASSURANCE PLAN
12 INCOMMING MATERIAL INSPECTION

Jamnagar
1. SCOPE OF WORK:
1.1 Mixing of Perlite, Cement and other required materials at site

using Mechanical drum mixer with required number of labourers
to make Perlite Concrete.
1.2 Carrying and Laying of Perlite concrete on designated area

directly.
1.3 Filling of gaps with Bitumen and Application of Bitumen on the

Top surface of the concrete where foam glass is free supply
and application is in our scope.
2. DIMENSION OF PERLITE CONCRETE ARE AS FOLLOWS:
 Outside Diameter of Perlite Concrete Ring : 36800 mm

(Tolerance +50mm & - 0.0)
 Inside Diameter of Perlite Concrete Ring : 34700 mm
(Tolerance + 0.0 & - 20 mm)
 Thickness of Concrete : 250 mm
 Center Part :1800 x 1800 x 250
mm
 Volume of Perlite Concrete Required : 30.3 M³
3. REFERENCE DOCUMENTS:
The following documents form an integral part of this Offer.
1. ASTM C 150 Type 1 – Portland Cement

2. ASTM C 332 – 09 Expanded Perlite
3. ASTM C 148M – 78 - Slump Test
4. ASTM C 138 – 92 (R2000) Wet Density Test
5. ASTM C 495-99a/C39/C39M-99 Compressive Strength Test
6. IS 3346 – 80 Thermal Conductivity
7. As per Technical Specification No.0217-EQS-75-EC-0003

Jamnagar
4. MATERIALS:
Material Classifications:
 Portland Cement OPC 43/53

 Perlite Aggregate ASTMC 332 Group 1
 Water Clean and free from deleterious
substances
 Air Entraining Agent As Recommended by KEL
 Reinforcing Fibre RecronFibre
The Properties of the Perlite Concrete blocks shall be as follows:
 Perlite Perlite/Cement Mix Concrete shall achieve the

Concrete Mix properties defined below
 28 day 45 – 55 Kg/cm2 After 28 days
Compressive
Strength
Cylindrical
Sample
 Oven Dry 900 – 1100 Kg/m3 After 28 days
Density
 Thermal 0.2 -0.25 W/mºK Maximum oven dried at 0ºC
Conductivity
 Wet Density 1000 – 1300 Kg/m3

Jamnagar
5. MIX DESIGN
The following is a typical mix design to produce a Perlite Concrete with

an over dry density of 900 – 1100 Kg/m3 and an average cube crushing
strength of 45 – 55 Kg/cm2. The following mixtures shall be adjusted to
get the final product quality.
A. Mix Ratio: 1Part Cement : 2.5 Part Perlite ( By Volume)
B. Mix Quantities : for 1 m³ yield
 Cement rapid hardening (IS 53 800 Kg

Grade)
 Expanded Perlite 150 Kg
6% Air Entertaining Agent 1.6 Liters
Water About 455 – 490 Liters
RicornFibre 1 Kg
In Process Control:
A: Mixing:
Mixing to be done using slow speed mechanical mixer (25RPM
Approx.)UsingRM 800 Mixer.
i) Cement slurry mixing time : 1 minute ( Water+AEA+Cement+Fibre)
ii) Perlite mixing time : 4 minutes (approx...)
The above mix shall produce a mix with the following characteristics.
C. :Wet Density : 1000 – 1300 Kg/m3

D. :Slump : 6 – 14Cms
Expanded Perlite Properties
EXPANDED PERLITE PROPERTIES

Expanded Perlite aggregate shall confirm to ASTM C 332 except as follows:
Density : 0.1 – 0.15 g/cc

Jamnagar
PERLITE CONCRETE
Perlite Concrete shall be made at site using Litemix Grade 55 of Expanded

Perlite, Cement AEA, Recron Fiber and Water.
6. APPLICATION & POURING
Clean the surface thoroughly and two coats of water base water proofing
shall be applied before pouring of perlite concrete. The Perlite concrete
mix is poured into the designated area manually. Wooden form shall be
installed on the deck slab along the annular ring in a continuous manner
to form a total ring. Wooden ply shall be used for partition (approx. 12
equal parts) in radial direction. This ply will be removed after the
initial setting of perlite concrete and the gap thus will work as
control/expansion joint. Leveling shall be done by using wooden or
aluminium leveling straight edge. Perlite concrete shall be cast in a
continuous manner to obtain thickness of 250 mm, which will be placed in
two layers. The first layer will be of 200 mm height and after 24 hrs.
the second layer will be cast to make up the balance height of 50 mm.
Flatness of the top surface shall be within +/-3 mm in 9 Meter length of
circumference and within +/-6 mm over the entire circumference.
Perlite concrete at the central part in the deck shall be cast

simultaneously. Wooden form shall be of 1800mm x 1800 mm x 250 mm. The
procedure for casting will be same as ring beam.
CURING:
The perlite concrete shall be allowed for curing for 7 days and natural
drying. Polystyrene Board 10 mm used for expansion joint shall be pulled
out after 3 days of curing.
SAMPLING:
Compressive Strength: One sample per day (2specimens of 75 mm dia x 150

mm height)
Oven Dry Density: One sample per day (2 Specimens of 75 mm dia x 150 mm
height)
The above Tests will be done after 28 days in our works and reports will
be submitted.

Jamnagar
7. REPORTS
A Certificate Compliance shall be issued with this specification along

with all the necessary test reports mentioned in this offer.
8. PROCEDURE FOR TANK BOTTOM
 After casting of the Slabs the area should be free from Moisture
 Application of one coat of Bitumenous Primer (BRP-5) on Dry Surface
 Alu foil 0.19 mm should be stuck with Hot Bitumen 85/25
 A Layer of Glass Fibre based Bitumen Felt (Tarfelt) shall be

applied with Hot Bitumen over the Aluminum foil
 The 1st Layer of foam glass blocks should be laid with Hot Bitumen
over the Tarfelt, and all joints should be sealed with Bitumen.
(Foam Glass thickness 100 mm )
 The 2nd Layer of foam glass blocks should be placed at an angle of

45º and all joints to be sealed with Bitumen. (Dry set) (Foam Glass
thickness 100 mm )
 Bitumen Layer of 1 mm should be given on top surface of the

foamglass.
 A Layer of Dry sand shall be spread over the Bitumen.

Jamnagar
9. INSPECTION AND TEST PLAN SHALL BE FOLLOWED AS PER TABLE BELOW :
Characteris Type of Quantum Acceptance Format Inspection by Remarks

tics Check Standards/ of LIIL TKIS GSFC
Ref. Record
Standards
Quality Doc. 100 Material QAP R R R
Control Review Spec.& PO
Plan Conditions
Raw Incoming 100 Quality Incomin R R R
Material Inspection Plan g
Inspect
ion
Report
Finished
Product
Inspection
Thermal TC Review Random Material Test R R R
Conductivit Sampling Spec& PO Report
y Conditions
Compressive Witness Random Material Test R R R
Strength, Sampling Spec& PO Report
Moisture Conditions
Content,
Oven Dry
Density
Data Book Doc Review 100 P.O. Data R R R
Conditions Book
LEGEND
R-Review (Submission of Documents for Review)
W-Witness (Witnessing of Inspection)

Jamnagar
10. SITE ORGANIZATION CHART
SUNEET P MUNJAL
DIRECTOR
SUKUMAR GUIN
SR GEN MANAGER
S MARTINS
GEN MANAGER
SITE MANAGER
DEVENDRA
THAPLIYAL
SAFETY SUPERVISOR
SAURABH
SITE SUPERVISOR ASHARAM DUBEY
CARPENTER (2 Nos.) SCAFFOLDERS (4 Nos.)
MASONS (4 Nos.) LAGGERS (8 Nos)
HELPERS (6Nos.) HELPERS (18 Nos.)

Jamnagar
11. QUALITY ASSURANCE PLAN
DOC NO. LIIL/TKIS/QAP/001

TKI
SI TEST PARTICULAR REQUIRED VALUES SPECIFICATION LLIL GSFC
S
1 PERLITE PROPERTIES
As per ASTM C ASTM C 332 - 17 Group
1.1 Perlite 332 - 1 P R R
As per ASTM C ASTM C 150 - 18 Type
1.2 Cement 150 1 P R R
Compressive
1.3 Strength 45 - 55Kg/cm2 in 28 days P R R
Thermal 0.2 - 0.25

1.4 Conductivity W/m•Kal P R R
1.5 Dry Density 900 - 1100 Kg/m3 P R R

1000 to 1300
1.6 Wet Density Kg/m3 P R R
1.7 Slump 6 to 14 Cm P R R
2 FOAM GLASS INSULATION
2.1 Alu. Foil 31000 Gr H3 IS : 737 P R R
2.2 Bitumen 85/25 IS : 702 Amend 1991 P R R

Grade 1 of Glass
Fiber Base
2.3 Tarfelt Bitumen felt IS : 7193 Amend 1999 P R R
Sand Chloride content approx. 200 ppm
2.4 P R R
Legend P = Perform / W - Witness / R = Review
PREPARED BY REVIEWED BY APPROVED BY

NAME :
DATE:
SIGNATURE

Jamnagar
12. INCOMMING MATERIAL INSPECTION
DOC NO. LIIL/TKIS/IMI/001

Quantit Invoice
Material Material Date of Heat
S.N Uni y /
Descriptio specification receive no./bat Remark
o t receive challan
n /Item code d ch no.
d nop.
100-150
1 Perlite kg
kg/m3 - - - -
OPC IS 49-53
2 Cement Kg
GRADE - - - -
3 Alu. Foil 0.19mm Kg

- - - -
4 Sand Kg
- - - -
5 Bitument 85/25 Kg
- - - -
Glass Fiber
Rol
6 Tarfelt Base Bitumen
ls - - - -
felt
Description
LIIL TKIS GSFC
Signature
Name
Date

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LLOYD INSULATIONS M/s.

Thyssenkrupp Industrial GSFC – Sikka, Jamnagar

APPLICATION PROCEDURE FOR

GUJARAT STATE FERTILIZERS &

LLOYD INSULATIONS (INDIA)

Doc. No. LIIL/TKIS/INSUL/001

Prepared By Approved by Reviewed By

Doc. No. LIIL/TKIS/INSUL/001 1

2 DIMENSION OF PERLITE CONCRETE

6 APPLICATION & POURING

8 PROCEDURE FOR TANK BOTTOM

9 INSPECTION AND TEST PLAN FORMAT

10 SITE ORGANIZATION CHART

11 QUALITY ASSURANCE PLAN

12 INCOMMING MATERIAL INSPECTION

Doc. No. LIIL/TKIS/INSUL/001 2

1.1 Mixing of Perlite, Cement and other required materials at site

1.2 Carrying and Laying of Perlite concrete on designated area

1.3 Filling of gaps with Bitumen and Application of Bitumen on the

2. DIMENSION OF PERLITE CONCRETE ARE AS FOLLOWS:

 Outside Diameter of Perlite Concrete Ring : 36800 mm

The following documents form an integral part of this Offer.

1. ASTM C 150 Type 1 – Portland Cement

Doc. No. LIIL/TKIS/INSUL/001 3

 Portland Cement OPC 43/53

The Properties of the Perlite Concrete blocks shall be as follows:

 Perlite Perlite/Cement Mix Concrete shall achieve the

Doc. No. LIIL/TKIS/INSUL/001 4

The following is a typical mix design to produce a Perlite Concrete with

A. Mix Ratio: 1Part Cement : 2.5 Part Perlite ( By Volume)

B. Mix Quantities : for 1 m³ yield

 Cement rapid hardening (IS 53 800 Kg

C. :Wet Density : 1000 – 1300 Kg/m3

EXPANDED PERLITE PROPERTIES

Doc. No. LIIL/TKIS/INSUL/001 5

Perlite Concrete shall be made at site using Litemix Grade 55 of Expanded

6. APPLICATION & POURING

Perlite concrete at the central part in the deck shall be cast

Compressive Strength: One sample per day (2specimens of 75 mm dia x 150

Doc. No. LIIL/TKIS/INSUL/001 6

A Certificate Compliance shall be issued with this specification along

8. PROCEDURE FOR TANK BOTTOM

 Application of one coat of Bitumenous Primer (BRP-5) on Dry Surface

 Alu foil 0.19 mm should be stuck with Hot Bitumen 85/25

 A Layer of Glass Fibre based Bitumen Felt (Tarfelt) shall be

 The 2nd Layer of foam glass blocks should be placed at an angle of

 Bitumen Layer of 1 mm should be given on top surface of the

 A Layer of Dry sand shall be spread over the Bitumen.

Doc. No. LIIL/TKIS/INSUL/001 7

9. INSPECTION AND TEST PLAN SHALL BE FOLLOWED AS PER TABLE BELOW :

Characteris Type of Quantum Acceptance Format Inspection by Remarks

Doc. No. LIIL/TKIS/INSUL/001 8

10. SITE ORGANIZATION CHART

SITE SUPERVISOR ASHARAM DUBEY

CARPENTER (2 Nos.) SCAFFOLDERS (4 Nos.)

MASONS (4 Nos.) LAGGERS (8 Nos)

HELPERS (6Nos.) HELPERS (18 Nos.)

Doc. No. LIIL/TKIS/INSUL/001 9

11. QUALITY ASSURANCE PLAN

DOC NO. LIIL/TKIS/QAP/001

Thermal 0.2 - 0.25

1.5 Dry Density 900 - 1100 Kg/m3 P R R

2 FOAM GLASS INSULATION