ROSTFREISTEELS LOGO

FBE Tanks

FUSION BOND EPOXY TANKS (FBE Tanks)

We use a state-of-the-art process to apply Resicoat Epoxy coating to mild steel sheets to prepare our Fusion Bond Epoxy Tanks. This cutting-edge technology enhances the intrinsic properties of steel, significantly improving its durability and performance. Bare steel is vulnerable to corrosive environments, but the epoxy fusion process fortifies it, extending the tank’s lifespan. Once fused, the epoxy coating elevates resistance to atmospheric weathering and corrosion, while broadening the acceptable pH range for the tank’s contents. FBE-coated tanks are versatile, making them suitable for storing a wide array of liquids, including potable water, wastewater, organic waste, and oils etc.

Rostfrei offers two variants of Fusion Bond Epoxy (FBE) Tanks:

 

1. FBEC Tanks (Rostfrei Patented Technology) with Liner – Corrugated Sheets

 

FBEC (Fusion Bond Epoxy Corrugated) liner tanks feature corrugated steel sheets where joint sealing is achieved using specialized nuts and bolts. Water is securely stored within a membrane liner bag fixed inside the tank shell, making these tanks suitable for heights up to 12 meters.

 

Sheet thickness ranges from 0.8–1 mm up to 2–2.5 mm, with higher thickness achieved through a sheet fusing process.

 

These tanks are typically installed and grouted on a reinforced concrete ring beam foundation, compacted and filled with sand at the center to enhance stability and support. This construction method provides an economical and reliable storage solution.

 

The internal liner serves as a protective barrier, shielding the tank from chemical reactions, corrosion, and external contaminants—significantly extending the service life of the tank.

WhatsApp Image 2024-04-18 at 16.36.12 (1)

2. FBE Tanks with Sealant – Plain Sheets

 

These Fusion Bond Epoxy tanks are constructed using plain steel sheets. Sheet joints are sealed using specialized nuts and bolts in combination with a PU sealant, creating a fully leak-proof system. These tanks are suitable for installations up to 25 meters in height.

 

Sheet thickness varies between 2 mm and 24 mm, depending on the tank’s design and structural requirements.

 

FBE tanks are installed and grouted on a full circular reinforced concrete foundation with integrated waterproofing, ensuring long-term durability.

The Fusion Bond Epoxy coating enhances resistance to harsh environmental conditions, providing excellent durability and making both FBE and FBEC tanks ideal for industrial, municipal, and agricultural applications where longevity and reliability are essential.

The Design Standards followed for FBE / FBEC tanks –

 

AWWA D103-09: This standard is published by the American Water Works Association (AWWA) and provides guidelines for the design, construction, and inspection of bolted steel tanks for water storage.

 

AS-2304:2019:  is an Australian standard that focuses on the design and construction of above-ground and underground storage tanks for liquids.

 

Adhering to these standards ensures that FBE/FBEC tanks meet the necessary safety, quality, and performance criteria required for various water applications. Compliance with standard code also helps ensure consistency and interoperability in the design and construction of FBE/FBEC tanks across different projects and locations.

Fusion Bond Epoxy Tank – PROCESS & TECHNOLOGY

A brief process of creating Fusion Bond Epoxy (FBE) tanks involves several precise steps to ensure the quality and integrity of the finished product:

tank

Nuts & bolt holes & manhole drilling / punching

Pre-Heating

Shot blasting process

Fusion-Process

Epoxy-coating on panels (inside and out) fused in a furnace with preheat (200°C–400°C) and post-bake (150°C–250°C) temperatures.

Post-Baking

Quality Check

       Here’s an overview of the typical quality check process – 

  • Spark Test
  • DFT
  • Impact test
  • Visual test (for liner)
  • Light test (for liner)

Installation Process

      A. Top-to-Bottom Assembly

  • Start by assembling the top ring and roof.
  • Use jacks to lift the structure.
  • Add subsequent rings from the top down by bolting them beneath the existing assembly.

    B. Adding Rings & Accessories

  • Continue ring installation, progressively adding new rings at the bottom as the structure is lifted.
  • Install ladders, manholes, nozzles, and other accessories during this stage, based on the tank design and layout.

    C. Anchoring

  • After full assembly, anchor the tank to the foundation.
  • Use J-bolts or chemical fasteners to ensure structural stability and resistance to uplift or lateral loads.

Types of Roofs We offer-

       1. Dome Roof – ZA / FBEC

       2. Conical Roof – ZA / FBE / GFS
       3. PVC Double membrane liner roof
       4. GFS fixed leakproof roof
       5. Geodesic Roof

MATERIAL CODES​

  • Sheet– IS2062.
  • Nuts And Bolts- ISO 898 – 1
  • Anchors– 8.8 Grade
  • PU Sealant– Migration Behaviour EN 1186, EN 13130, CEN/TS 14234, ISEGA, Certificate No. 46763 U 18
    Sewage Installations wastewater, As Per Report No 36142/98

Fusion Bond Epoxy Corrugated Liner Tank – Process and Technology

tank

Sheet Corrugation - Steel sheets are processed through a corrugation machine at our facility. This step enhances the flexibility and structural strength of the steel panels, resulting in a more robust tank design.

Fusion-Process

Cutting, Drilling and Curving - The corrugated sheets are cut into the required panel sizes. They are then machined on advanced CNC and drilling equipment for precise hole placement. Finally, the panels are shaped using a curving machine to meet the specified design.

Heat-Furnace

Coating Process

  • Surface preparation via sandblasting
  • Pre-heating at 200°C–250°C
  • Epoxy coating application
  • Final baking at 150°C–250°C for curing
Installation-process

Installation Process

            A. Top-to-Bottom Assembly
            B. Adding Rings, along with Liner & Accessories
            C. Anchoring

FUSION BOND EPOXY CORRUGATED TANK (liner tank)

KEY ADVANTAGES OF ROSTFREI’S FBE TANKS

APPLICATIONS OF FUSION BOND EPOXY TANKS

Fusion Bond Epoxy Tanks offer extensive applications across various application & industries. Some are mentioned below:

COLOR OPTIONS AVAILABLE

Rostfrei GFS tanks are available in three colour options.