Tank Fabrication Companies
Tank fabricators across all materials and applications: GRP/FRP, HDPE, stainless steel, concrete, and glass-lined storage and process tanks.
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Ecosystems International
VerifiedIndonesia · 51-200 employees
PT Ecosystems International (PT ESI) was established at Jakarta on 21st November 2006. We are an industrial effluent treatment systems integrator specializing in electrocoagulation (EC), a unique waste water treatment profile. PT ESI has capabilities in designing complete waste water treatment solutions by combining various effluent treatment systems such as the electro-coagulation, biological, chemical processes and membrane filtration, offering its customers a wide and comprehensive range of solutions, tailored to suit their various needs – ranging from basic effluent treatment for discharge to effluent recycling for water reuse. The Company is experienced in handling the design, engineering, procurement, construction and operation of new Effluent Treatment Plants (“ETP”) and possesses expertise in retrofitting existing ETP to increase the flow rate and treatment capability without any major infrastructure increase PT ESI is also a premier waste water treatment service company specializing in handling waste water generated from Exploration (Drilling) and Produced Water. Customers in Indonesia include major Oil & Gas companies such as Pertamina, Exxon, Chevron, Petro-China and Medco. Operations in Indonesia are provided by both mobile and fixed units. At drill sites where waste-water recycling is required, PT ESI supplement these treatment units with skid mounted mobile Reverse Osmosis systems. The technologies and solutions employed by PT ESI are developed in-house and examples of these are its proprietary Trident™ Electro Contaminant Removal (“ECR”) system, the Stage Contaminant Removal (“SCR”) process and Mobile On-Site Waste-Water Treatment (“OWT”) units
Buyer's guide
The buyer's guide to tank fabrication
Water and Wastewater Tank Fabrication: Standards, Materials, and Design Specification
Tank fabrication for water storage, wastewater treatment, and industrial process applications encompasses a wide range of materials, sizes, and design standards. Steel tanks: welded steel tanks are the most common large-volume solution; carbon steel (ASTM A36, BS EN 10025 S275, S355); bolted steel (corrugated or smooth panel, factory powder-coated or hot-dip galvanised (HDG) to BS EN ISO 1461; field-assembled from sections; typical diameters 2 to 20 m; heights to 6 m; capacities 5 to 2,000 m3); welded steel (API 650 for atmospheric storage tanks; BS EN 14015 for above-ground welded steel flat-bottom vertical cylindrical tanks; capacities to 100,000 m3 for large reservoirs; foundation requirements: ring beam for large tanks, engineered granular pad for smaller; settlement monitoring for post-construction).
Stainless steel tanks: 304 or 316L stainless for food, beverage, pharmaceutical, and high-purity applications; hygienic design to EHEDG (European Hygienic Engineering and Design Group) guidelines; electropolished interior finish Ra less than 0.8 um; orbital welded joints; certification to PED 2014/68/EU for pressure tanks or AS/NZS 1692 for atmospheric. Concrete tanks: reinforced concrete (BS EN 1992, Eurocode 2); prestressed concrete (BS 8007, design of concrete structures for retaining aqueous liquids); cast in-situ or precast (BS EN 14843 for precast reinforced concrete tanks); capacities from 10 m3 (precast) to millions of m3 (in-situ reservoir); watertightness class W1 or W2 per BS EN 1992-3.
GRP (glass reinforced plastic) and thermoplastic tanks: GRP tanks (filament wound or hand lay-up; BS EN 13121-3 for above-ground GRP tanks; BS 4994 for GRP vessels for chemical processes; design pressure atmospheric to 1 MPa; diameter 0.5 to 10 m; chemical resistance superior to steel for acids, alkalis, and chlorinated compounds; weight 60 to 80 percent lighter than equivalent steel; lifespan 20 to 50 years with UV-stable gelcoat; glass/polyester or glass/vinyl ester resin systems; fire classification B-s2, d0 to Euroclass E per BS EN 13501-1); HDPE and polypropylene tanks (rotationally moulded for small volumes 100 to 30,000 L; fabricated for larger volumes; USP Class VI plastics for pharmaceutical contact; FDA-approved HDPE for food contact; chemical resistance chart (HDPE: suitable for HCl, H2SO4, NaOH, chlorinated solvents at concentrations to 30 percent; not suitable for aromatic hydrocarbons, strong oxidising acids above 30 percent)). Coatings and linings: internal coatings protect carbon steel from corrosion and provide chemical resistance; DWI/WRAS-approved drinking water coatings (NSF/ANSI 61 certified): approved epoxy systems from the established manufacturers; coal tar epoxy (AWWA C210) for raw water storage; rubber lining (chlorobutyl, EPDM, natural rubber) for aggressive chemical service; glass fused to steel from the established manufacturers for municipal wastewater tanks (bioglass or enamel coating at 850 degrees C fused to steel panels; AWWA D103 standard for factory-coated bolted steel tanks).
Tank design parameters and inspection: design life for water utility tanks: 50 to 100 years (concrete), 25 to 40 years (steel), 30 to 50 years (GRP); inspection regime: Water UK's Asset Management plans require regular inspection of service reservoirs and storage tanks; EA and DWI guidance on reservoir inspection (Large Reservoirs Act 1975 applies to impoundment reservoirs over 25,000 m3); annual inspection (visual); 10-year inspection (structural, with dewatering and confined space entry); ultrasonic thickness measurement of steel walls and floors (acceptance criterion: residual wall thickness greater than 75 percent of original design thickness). Testing: hydrostatic test before commissioning (fill with water, hold 24 to 72 hours, measure settlement and leakage; acceptance: less than 0.1 percent volume per 24 hours for watertight design); vacuum test of weld seams (0.02 MPa negative pressure applied to weld seam with soap solution; BS EN 14015 Clause 12); non-destructive examination of welds (radiographic (RT) or ultrasonic (UT) per API 650 Section 8 and 9; typically spot RT on 10 percent of butt welds for standard tanks). UK tank fabricators: a range of established suppliers cover glass-fused-to-steel and bolted steel, rotationally moulded plastic, GRP, and modular tanks.
Frequently asked questions
What standards apply to water storage tank fabrication in the UK?
UK water storage tank fabrication standards: Above-ground welded steel flat-bottom tanks: BS EN 14015:2004 (specification for the design and manufacture of site built, vertical, cylindrical, flat-bottomed, above-ground, welded, steel tanks); API 650 (welded tanks for oil storage, also widely used for water); BS EN 1993-1-6 (design of steel structures, cylindrical shells, for shell buckling). Bolted steel tanks: AWWA D103 (factory-coated bolted steel tanks for water storage); BS EN 1993-1-6 applies to shell design. Concrete tanks: BS EN 1992-3:2006 (design of concrete structures for liquid retaining and containment); BS 8007:1987 (design of concrete structures for retaining aqueous liquids - withdrawn but still referenced); BS 8500 (concrete specification); watertightness class W1 (leakage through cracks limited to 0.1 percent volume of stored liquid per day) or W2 (no leakage through cracks). GRP tanks: BS EN 13121-3:2016 (underground and above-ground GRP tanks, design); BS 4994:1987 (GRP vessels and tanks for chemical processes - key design document for chemical service); LPS 1500 (Loss Prevention Certification for GRP tanks used in fire suppression). Pressure vessels (tanks operating above 0.5 bar): PED 2014/68/EU (Pressure Equipment Directive, UK retained PSSR 2000 and PED SIs); BS EN 13445 (unfired pressure vessels). Drinking water contact: all materials (tank linings, gaskets, coatings) must be DWI/WRAS approved (BS 6920 extraction test; NSF/ANSI 61 as alternative route). Reservoirs over 25,000 m3: Reservoirs Act 1975 (supervision by qualified civil engineer; inspection by independent panel engineer).
What internal coatings are approved for drinking water tanks?
Internal coatings for drinking water contact tanks must be approved by the Drinking Water Inspectorate (DWI) under the Water Supply (Water Quality) Regulations 2016 (England) and equivalent Regulations in Wales, Scotland, and Northern Ireland. DWI/WRAS approval process: coating system submitted for testing under BS 6920 (suitability of non-metallic products for use in contact with water intended for human consumption); tests assess effect on taste, odour, appearance, and concentration of substances leaching into water; approval granted for specific substrate and coating thickness; coating must be applied by trained applicator according to DWI-approved product data sheet; DWI maintains approved products list. Key approved drinking water contact coatings: (1) Epoxy coatings: cold-cure epoxies (DWI approved); amine-cured epoxies; solvent-free epoxies for water tanks (NSF/ANSI 61 listed); (2) Glass fused to steel: proprietary systems from the established manufacturers (enamel fused to corrugated steel panels at 850 degrees C; AWWA D103 standard; no organic coating; lifelong water contact approval; used for potable water reservoirs and STW sludge tanks); (3) Polyurethane coatings: submersible grade polyurethanes (DWI approved for water contact); (4) Cementitious linings: sulphate-resisting Portland cement mortar (BS EN 206; BS EN 1504-2 for concrete surface protection; approved for concrete tanks); (5) WRAS approval: independently tested by WRc, BBA, or other UKAS-accredited body; WRAS Approved Products list searchable at wras.co.uk.
How are large concrete water storage tanks designed?
Large concrete water storage tanks (service reservoirs, balancing tanks, contact tanks) are designed to BS EN 1992-3:2006 (Eurocode 2, Part 3: liquid retaining and containment structures). Design process: (1) Site investigation: ground conditions (bearing capacity for foundation design; settlement analysis; groundwater level; contamination); seismicity (BS EN 1998-4 for tanks in seismic zones). (2) Structural loads: hydrostatic pressure (rho x g x h, where rho = 1,000 kg/m3 for water, 1,025 kg/m3 for seawater; factored by gamma_F = 1.2 to 1.35); earth pressure on buried sections (Rankine or Coulomb active pressure); groundwater buoyancy (uplift = gamma_w x h_w x area; uplift resistance by self-weight and tension piles if insufficient); temperature gradients; concrete shrinkage and creep (long-term effects significant for crack width control). (3) Crack width control: BS EN 1992-3 watertightness class W1: maximum crack width 0.2 mm (under rare load combination); minimum crack width 0.05 mm for W2; reinforcement designed to limit crack widths using minimum steel percentages (0.2 to 0.4 percent of cross-sectional area depending on element thickness); cover to reinforcement: 40 to 50 mm nominal for XC4/XS1 exposure class. (4) Wall thickness: typical 200 to 500 mm for service reservoir walls depending on height and span; base slab 250 to 600 mm; prestressed concrete allows thinner sections (wall 150 to 300 mm). (5) Joint design: movement joints every 20 to 30 m (waterstop: proprietary type; 250 to 300 mm wide PVC or HDPE; fully bonded to concrete); construction joints (roughened surface, 20 mm aggregate exposure; continuity reinforcement; PVC or steel flat waterstop).
What is glass-fused-to-steel and why is it used for water tanks?
Glass-fused-to-steel (GFS) is a tank construction method where vitreous enamel coating (silicon dioxide-based glass compound) is fused to steel panels at kiln temperatures of 820 to 870 degrees C, creating a chemically bonded glass-steel composite with superior corrosion resistance and a smooth, non-porous surface. Manufacturing process: steel panels (3 to 12 mm, corrugated or smooth) cleaned and acid-etched; glass slip (powdered glass compound) applied by spray or electrostatic deposition; fired in kiln at 840 to 860 degrees C for 3 to 6 minutes; glass melts and bonds to steel surface; typical coating thickness 200 to 500 um; process repeated for second coat application; factory inspection (holiday test, 1,000 to 1,500 V DC spark test to BS EN ISO 8289; pinhole-free surface required). Field assembly: prefabricated panels (typically 1.2 to 2.4 m x 0.9 to 1.2 m) bolted together with EPDM or silicone gaskets (WRAS/DWI approved); typical bolt pitch 150 to 200 mm on flanges; bolt tensioning to manufacturer's specification (typically 25 to 50 Nm); no field welding required (reduces on-site quality risk). Advantages: DWI approved for drinking water contact (no organic coating required); life expectancy 30 to 50 years with inspection and gasket maintenance; resistant to biofouling (smooth glass surface, Ra less than 0.5 um); resistant to UV degradation; field assembly without hot work permits (important for explosion-risk sites); disadvantages: higher unit cost than painted steel (typically 1.3 to 1.8 times premium); potential for panel damage during transport; chip repair required if glass damaged. Standards: AWWA D103 (factory-coated bolted steel tanks for water storage); A small number of established manufacturers supply the UK market. Applications: potable water reservoirs (500 to 5,000 m3), STW sludge digestate tanks, anaerobic digestion tanks, biogas storage.
Illustrative scenario · Municipal drinking water
A composite drawn from typical projects in this category, not a single client engagement. Figures are indicative.
- Challenge
- A water company in the South West needed to replace a 4,000 m3 reinforced concrete service reservoir that had reached end of structural life (carbonation depth exceeding 55 mm cover, crack width 0.35 mm in hogging zones). The site was operational and the reservoir was the sole balancing storage for 28,000 properties; supply could not be interrupted for more than 72 hours.
- Approach
- A GFS bolted-steel replacement reservoir (4,200 m3, 20.4 m diameter, 14.5 m wall height) was erected alongside the existing structure while it remained in service. Panel delivery was scheduled in 6 shipments to fit the A30 access road constraints. All WRAS-approved EPDM gaskets were pressure-tested at 1.1 bar after assembly. The existing concrete reservoir was decommissioned and demolished only after the GFS tank had passed a 72-hour hydrostatic test and DWI-notified microbiological clearance.
- Outcome
- The new reservoir was operational within 14 weeks from panel delivery; supply was interrupted for only 8 hours during the final connection to the trunk main. The GFS tank required no internal coating application, eliminating 12 weeks of coating cure and DWI extraction testing. Whole-life cost comparison showed GFS at GBP 420/m3 installed versus in-situ concrete at GBP 580/m3 for this site, despite a higher per-panel material cost.
Questions to ask shortlisted providers
5
- 01
Is the proposed tank material WRAS-approved for drinking water contact and can you provide the current DWI Approved Products List reference?
Organic epoxy linings require periodic re-inspection and recoating; GFS avoids this cycle but must be confirmed on the current WRAS Approved Products List, as approvals are product-specific and expiry-dated.
- 02
What gasket material do you specify and how often should gaskets be replaced under your recommended maintenance programme?
EPDM gaskets in potable water tanks typically need replacement at 15 to 20 years; deferred gasket replacement is the primary cause of GFS tank leakage; the lifecycle cost of gasket replacement must be included in the whole-life cost comparison.
- 03
How is the tank foundation designed for differential settlement and what bearing pressure does the design assume?
A GFS or welded steel tank on a weak clay site can experience differential settlement that opens panel joints; the foundation engineer must be engaged before tank size and layout is finalised.
- 04
What is the hydrostatic test protocol and what does it include beyond a simple fill-and-hold test?
BS EN 14015 requires measurement of settlement during fill; vacuum testing of weld seams (for welded tanks); DWI also requires a microbiological clearance sample before water enters supply from a new tank.
- 05
Does the tank design comply with BS EN 1992-3 or AWWA D103 and which code will the structural calculations be certified to?
For concrete tanks, BS EN 1992-3 watertightness class W1 is the UK standard; for bolted steel tanks, AWWA D103 governs; mixing codes in the same structure or supply chain creates certification gaps that DWI inspectors identify during routine audits.
What drives cost in this category
4
- Material type and unit cost per m3 capacity
- GFS bolted steel costs GBP 300 to 500/m3 installed for 1,000 to 5,000 m3 tanks; in-situ reinforced concrete costs GBP 450 to 700/m3; the cross-over point at which concrete is cheaper depends heavily on ground conditions (poor bearing capacity favours smaller GFS panels with distributed loads over concrete slab).
- Foundation type and ground conditions
- A concrete ring beam for a 4,000 m3 GFS tank on clay costs GBP 80,000 to 150,000; a piled foundation for very soft ground adds GBP 120,000 to 300,000; these civils costs are frequently omitted from initial budgets based on supply-only tank quotations.
- Internal coating specification and application
- Epoxy internal coatings for carbon steel tanks cost GBP 25 to 60/m2 in materials and application; DWI extraction testing adds GBP 5,000 to 15,000; re-coating every 10 to 15 years adds a lifecycle cost of GBP 80,000 to 250,000 NPV over a 50-year asset life, which GFS eliminates.
- Access road and cranage constraints
- Abnormal-load transport of large welded steel sections or pre-assembled tank modules may require highway improvement at GBP 30,000 to 120,000; GFS bolted panel kits arrive in standard flatbed loads and can access most rural sites without highway restriction.
Key regulations and standards
4
- BS EN 14015 and AWWA D103 for Tank Design
- Above-ground welded steel flat-bottom tanks must be designed to BS EN 14015 (UK/EU standard) or AWWA D100/D103 (US standard widely accepted in UK for bolted GFS tanks); structural calculations must be certified by a chartered structural engineer and retained in the project file.
- WS(WQ)R 2016 and WRAS Approval for Drinking Water Contact
- All materials in contact with water intended for human consumption must be WRAS-approved under BS 6920 extraction test criteria; tank construction materials (gaskets, coatings, inlet/outlet fittings) must be confirmed on the current WRAS Approved Products List before being used in potable water service.
- Reservoirs Act 1975 (Large Raised Reservoirs)
- Service reservoirs with more than 25,000 m3 capacity held above natural ground level are prescribed reservoirs under the Reservoirs Act 1975; they must be supervised by a qualified civil engineer and inspected by a Panel Engineer from the ICE Reservoirs Act Panel every 10 years; the EA can require immediate safety measures if the reservoir is found unsafe.
- CDM 2015 (Health and Safety File)
- Tank construction projects involving more than one contractor require a Principal Designer (CDM 2015) to coordinate H&S during the design phase and compile a Health and Safety File at project completion; the File must document: foundation design, tank material specifications, gasket replacement procedures, confined space entry protocols, and inspection access requirements.