CATHODICALLY PROTECTED UNDER-

GROUND STORAGE TANKS

R821 INSTALLATION INSTRUCTIONS

February 2017
1.0 EXCAVATION AND BEDDING 2.0 AIR TEST AT JOB SITE
1.1 The bottom of the excavation shall be covered with a minimum 2.1 Temporary plugs and thread protectors installed by the manu-
of 12 inches (305 mm) of bedding, suitably graded and leveled. facturer shall be removed. Apply compatible, non-hardening
Bedding and backfill material surrounding the tank, to a width pipe sealant to internal bushing threads. Permanent metal plugs
and depth of 12 inches (305 mm) all around the tank, shall be shall be installed at all unused openings.
clean material.

2.2 If the manufacturer has shipped a double wall tank with a vacuum on
the interstitial space, read and record the vacuum pressure. If the
vacuum gauge reading has dropped more than 2 inches Hg (6.77
kPa), from the level at which it was shipped, contact the tank
manufacturer.
2.3 To conduct a soap solution/air pressure test, follow these steps:
1. The nylon bushings in sti-P3® tanks shall not be removed from
the unused openings. Plugs used to temporarily seal the tank for
the above ground air test, but later removed for pipe installation,
shall not be over tightened. Do not cross thread or damage the
nylon bushings when replacing plugs or installing required tank
piping.
2. Test pressure shall be maintained at, without exceeding, 5 psig
(34.47 kpa) while a soap solution is applied to the area of pipe
1.2 Steel thickness can be calculated for the required burial depth. connections and welds.
1.3 Where anchoring by means of a concrete pad, the tank shall not 3. Dual wall tanks shall require different air pressure testing
be placed directly on the pad. Bedding material at least 6 inches procedures. Do not connect a high pressure air line directly to
(152.4 mm) deep must be spread evenly over the dimensions of the interstitial monitoring port. A factory applied vacuum within
the pad to separate the tank from the pad. the interstitial space can be used in lieu of, or in addition to, the
1.4 Bedding and backfill material shall consist of homogenous pea air test procedure. Consult tank fabricator for air test
gravel, crushed stone, clean sand, natural earthen materials, or recommendations. Do not apply a vacuum to the primary tank or
excavatable flowable fill. Crushed stone, clean sand and natural a single wall tank. PEI/RP 100-00 also provides guidelines.
earthen materials shall be capable of passing 100% through a 1/2 4. Take necessary safety precautions during air tests. Do not leave
inch (13 mm) sieve and no more than 12% by dry weight through tanks unattended. Avoid standing at the head of the tank,
a #200 sieve (0.0029 inch (0.0754 mm)). Pea gravel shall be no especially while applying air pressure. Use an air- pressure relief
larger than 3/4-inch (19 mm). Flowable fill shall meet the National valve.
Ready Mixed Concrete Association for Controlled Low Strength
materials (CLSM) with strength ranging from 70-150 psi and shall
be installed in accordance with good engineering practice. The
materials shall be free of all foreign materials, such as but not
limited to, bricks, metals, concrete and plastics.
1.5 The backfill material may be from the tank site if it meets this
description, or it may be delivered to the site from another source.
1.6 Sand or natural earthen materials used as backfill shall be placed
into the excavation in 12-18 inch (305-458 mm) vertical lifts,
compacted after each lift, at least 60% up the vertical height of
the tank.
1.7 If earthen material from the site, or other earthen material, is to be
used as bedding or backfill material, a minimum of four 1 cu.ft.
samples shall be taken from different locations which are
representative of the backfill material and the site. Samples shall
be sieved to determine if the material complies with this
specification. 2.4 In lieu of the air pressure test described above, a vacuum may be
1.8 In a tidal area, the tank "bedding" material shall be crushed stone applied to the interstice of a double-wall tank. DO NOT APPLY A
or pea gravel. Sand and natural earthen material may be used VACUUM TO THE PRIMARY TANK OF A DOUBLE-WALL TANK OR
only if measures are taken to prevent washout of material during TO A SINGLE-WALL TANK. A vacuum of 6 inches Hg (20.3 kPa) is
the design life of the system. to be applied to the interstice. The vacuum shall be held without a
loss for one hour on tanks less than 20,000 gallons and for 2 hours
 for tanks greater than or equal to 20,000 gallons. If this vacuum 5.3 After an sti-P3® tank has been placed in the excavation, if anode
cannot be held for the specified time interval, then perform the air is connected by a lead wire, attachment to the tank shall be
test procedure described in section 2.3. checked to assure this connection has not been damaged.
Where damaged, the connection must be re-established in strict
accordance with this specification.
3.0 COATING INSPECTION
3.1 Before placing the tank in the excavation, all dirt clods and similar
foreign matter shall be cleaned from the tank, and areas of coat-
ing damage shall be repaired with touch-up coating kit provided.
3.2 Clean damaged coating areas through removal of surface rust,
dirt, contaminants and disbonded coating prior to application of
touch-up coating (see SSPC SP-2 "Hand Tool Cleaning" or SP-3
"Power Tool Cleaning" for additional guidance).

5.4 To assure immediate operation of cathodic protection system,

each anode shall be thoroughly saturated with water at time of
backfill operations.

4.0 TANK HANDLING & PREPARATION 6.0 ANCHORING

4.1 Controlled off-loading of the tank shall be allowed. 6.1 High water tables or partially flooded excavation sites exert
4.2 Equipment to lift the tank shall be of adequate size to lift and significant buoyant forces on tanks. Buoyant forces are partially
lower the tank without dragging or dropping to ensure there is no resisted by the weight of the tank, the backfill and the pavement
damage to the tank or the coating. atop the tank. Additional buoyant restraint, when required, shall be
4.3 Tanks shall be carefully lifted and lowered by use of cables or obtained by using properly designed hold- down straps in
chains of adequate length attached to the lifting lugs provided. A conjunction with concrete hold-down slabs or deadman anchors.
spreader bar shall be used where necessary. Under no The use of steel cable and/or round bar as hold-down straps on
circumstances shall chains or slings be used around the tank the tank is prohibited.
shell.
6.2 If a metallic hold-down strap is used, a pad of inert insulating di-
electric material must be used to insulate the hold-down strap
from the tank. The separating pad shall be wider than the hold-
sown straps, which will prevent direct contact between the straps
and the tank shell. This pad is not required if the hold-down strap

4.4 Follow label instructions including those at tank openings.

4.5 This tank requires venting. Refer to applicable local codes and
PEI RP-100 for proper installation.
6.3 Ballasting the tank may be necessary. When water is used as the
ballast material, it shall only be potable water and shall not re-
5.0 ANODE INTEGRITY
main in the tank longer than 60 days. During construction, ade-
5.1 sti-P3® tanks may be equipped with either zinc or magnesium
anodes. Whereas magnesium anodes are designed only for quately vent all tank spaces. If product is used as ballast, proper
installation in soil resistivities of 2000 ohms-cm or greater, zinc precautions must be taken to prevent fires, spills, leaks, and
anodes are effective in all soil resistivities. other associated accidents. Monitor product level frequently to
5.2 After a sti-P3® tank has been placed in the excavation, if anode is ensure there has been no unaccounted loss of product. Do not
connected by a lead wire, attachment to the tank shall be
checked to assure this connection has not been damaged. over tighten hold-down straps beyond snug and do not re-tighten
Where damaged, the connection must be re-established in strict hold-down straps after ballasting.
accordance with this specification.
7.0 BACKFILL 9.0 TANK MONITORING SYSTEM INSTALLATION
7.1 Homogeneous backfill similar to bedding material shall be 9.1 Each tank shall have a cathodic protection monitoring station
placed carefully around the entire tank to create a uniform ho- (PP4®, PP2®, PP1®, or other) installed in such a way so that
mogeneous environment. Avoid damage to coating especially there will be at least a tank structure lead easily accessible and
where tamping is required. identifiable at the finish grade and provide easy placement of a
7.2 Installing and tamping backfill along the bottom sides of the tank reference electrode during monitoring.
shall ensure that the tank is fully and evenly supported around 9.2 If your tank is equipped with a Protection Prover 4 (PP4®), re-
the bottom quadrant. move the unit from the shipping carton and inspect for damage.
(See the separate manufacturers’ installation instructions for
specific details.)

9.3 Prior to installation of the PP4®, remove the plastic bag from the
reference cell element. After the tanks have been placed in the
excavation, position the reference cell element midway from
front to back between two tanks so that it is covered by 6 inches
(152 mm) of moist bedding material.

7.3 Prior to backfilling to top of tank, all openings shall be visually

inspected to assure that the sti-P3® nylon bushings remain in
place. Where flanged openings have been used, isolation of the
flange gaskets shall be confirmed with a continuity tester. No
current shall pass through the factory installed flange gaskets.
Isolation of the fittings is required to assure tank integrity. If the
tank is to be installed in the presence of an impressed current
system, the effect of the system must be considered on the sti-
P3® tank. The corrosion consultant must consider including the
sti-P3® tank into the design of the impressed current system.

9.4 Drape the flexible pipe up to the top of the tank and temporarily se-
cure the pipe to prevent damage during backfill operations. Backfill
the excavation until the tanks are almost covered.
9.5 Locate the PP4® test head in its approximate final position and sup-
port with a wooden stake or other similar device. Connect the appro-
priate tank test wire from the reference cell element to the black test
lead already installed on the tank using the hardware supplied or by
performing a field splice.
9.6 Assure that the wire connection is strong by simultaneously placing
tension on the wire at either side of the connection point. Protect the
wire connection from corrosion using the material supplied with the
PP4® or by wrapping the connection in half lapped layers of rubber
and PVC electrical tape.
8.0 FINAL AIR TEST
8.1 Install required tank piping using compatible non-hardening seal-
ant, taking care not to cross thread or damage the non-metallic
bushings. Torque of 400 to 1,000 ft-lbs (542.3 to 1355.8 N-m)
may be required to fully insert pipe.
8.2 Where air or hydrostatic testing is required after installation, the
pressure applied shall not be in excess of 5 pounds per-square-
inch (34.5 kPa) as measured at the top of the tank. A soap solu-
tion shall be applied around pipe connectors while air test is
being performed.
 9.7 Assure that the wire connection is strong by simultaneously 11.0 FINAL BACKFILL
placing tension on the wire at either side of the connection 11.1 Homogeneous backfill shall be deposited carefully around the
point. Protect the wire connection from corrosion using the ma- tank and to a depth of at least one foot (305mm) over the tank.
terial supplied with the PP4® or by wrapping the connection in (See NFPA 30 and state or local codes for minimum depth of
half lapped layers of rubber and PVC electrical tape. cover required).
9.8 The test head shall be placed in a small grade manhole to pro-
tect it from vehicular traffic or set directly in the concrete cover-
ing for the excavation. During pouring of the at-grade slab pro-
tect the metal contact points on the test head from being cov-
ered by concrete.
1. Select a terminal location on a pipe near grade that will be
accessible through a grade manhole upon completion of instal-
lation.
2. Loosen the black nylon pipe lashing by releasing the locking
tab. Uncoil enough lead wire from the tank mounting lug to
reach the terminal location with an additional 4 feet (1.2 m) of
slack.
3. Secure the PP2® terminal to the pipe by tightening the black
nylon pipe lashing. The lead wire terminations shall remain
sealed.
4. Route wire to avoid strain or breakage during backfill. Do not
cover PP2® terminal with backfill material. 12.0 POST-INSTALLATION CATHODIC PROTECTION MONITORING
12.1 All tanks must be monitored to assure proper installation and
ensuing cathodic protection of the tank. Before pouring concrete
or asphalt pad atop tank, a tank to soil potential reading with a
high impedance voltmeter and copper/copper sulfate reference
electrode must be taken. Reference electrode shall be placed in
moist soil directly above the tank. A minimum reading of -850
millivolts should be obtained to indicate that the tank anodes are
activated. Record reading on installer information card and other
permanent files.

9.9 If the tank is equipped with a Protection Prover 1 (PP1®)

monitoring system, which includes a monitoring test station
mounted at the end of the tank, prior to any backfilling, extend the
monitoring system to 4 inches (102 mm) below grade level without
pulling it out of the mounting bracket. The PP1® test station shall
be protected by a grade manhole of 7½ inches (191 mm)
minimum diameter.

12.2 If the tank is connected to a PP4® test station the cathodic protec-
tion can be easily verified using a high impedance digital volt-meter.
Touch the meter probes to the appropriate test head terminals as
shown in the diagram above. As stated in 12.1, a minimum reading
of -850 millivolts should be obtained.

10.0 ELECTRICAL CONTINUITY TEST

10.1 Contact between the steel tank and all other structures such as
external and internal piping, pumps, valves, gauge, and monitoring
equipment, and grounding systems, will nullify the cathodic protec-
tion design. Prior to backfill, a simple continuity test between the
tank lead wire and each connected system will verify the electrical
isolation. Continuity shall not be present. After backfill, continuity
can be checked with a high impedance voltmeter by fixing a cop-
per/copper sulfate reference cell in the soil and contacting all struc-
tures with the other voltmeter lead wire. Do not move the reference
cell. Potential differences between the tank to soil and all other
structures to soil must exceed 10 millivolts to verify electrical isola-
tion.
13.0 OPERATING LIMITATIONS Disclaimer
Operation of the tank above 120oF (49oC) requires the use of specific
components and materials. The tank manufacturer must be notified, These instructions are intended only as an aid to tank
prior to tank use, of the owner’s intent to operate this tank above installers who are knowledgeable and experienced in
120oF (49oC) so that proper components and materials can be incor- underground tank installation. Compliance herewith
porated. does not necessarily meet the requirements of appli-
13.1 When the product stored is heated, the temperature inside the tank cable federal, state and local laws, regulations and
shall be constantly monitored to assure the maximum allowable tem- ordinances concerning tank installation. STI makes
perature is not exceeded. no warranties, express or implied, including but not
limited to, any implied warranties of merchantability
or fitness for a particular purpose, as a result of these
14.0 MAINTENANCE installation instructions.
14.1 The primary tank shall be inspected monthly for the presence of wa-
ter. Inspection shall take place at the lowest possible points inside the Contact STI for the latest version of these Installation
primary tank. Remove any water found. Water and sediment in fuel Instructions or visit the STI website at
can cause plugging of filters. Also, bacterial growth, originating from www.steeltank.com.
the fuel can cause filters to plug and corrosion of tanks and lines. For
procedures on how to check for the presence of water and removal of
water, refer to STI R111, Storage Tank Maintenance. For copies of
the RP and more information, please go to www.steetank.com.
14.2 sti-P3® tanks shall be tested for cathodic protection at installation, in 3
year intervals for the life of the installation and after any activity that
might affect the CP system. sti-P3® tanks which might otherwise be
classified as ACT-100® composite tanks, due to factory attachment of
anodes, do not require testing every third year. In addition, double-
wall sti-P3® systems that use interstitial monitoring that is capable of
detecting a breach of either tank wall, do not require testing every
third year. (See EPA UST technical Compendium for complete details
www.epa.gov/swerust1/compend/nus18lh.pdf). Follow applicable
local, state, and federal regulations for any additional requirements.
Reference NACE RP-0285 for more specifics on protection criteria.
14.3 Tank must be installed within one year of delivery from tank manufac-
turer. If tank is not installed within this time period, contact tank man-
ufacturer to recertify the tank.
14.4 Safety considerations and controls should be established prior to
undertaking physical activities associated with USTs. Some hazards
associated with USTs are, but not limited to, confined space entry,
cleaning, inspection, moving and any other aspect of in-service work.
 Contact tank manufacturer before moving tank for information on
recertifying tank for continued use.
 CATHODICALLY PROTECTED
UNDERGROUND STORAGE TANKS

R821
INSTALLATION CHECKLIST
February 2017
Owner of Tank: sti-P3® Label No.:
Location of Tank: Date:

CHECK ( ) CHECK ( )
HANDLING

The handling equipment is of adequate size and capacity to Tank is electrically isolated from the hold down strap.
lift and lower the tank without dragging or dropping

The repair of any damaged laminate areas has been BACKFILL

made in accordance with installation instructions Homogenous backfill consisting of clean sand,
pea gravel, #8 crushed stone or material earthen material
Plastic wrap has been removed from the weld-on zinc anode has been used
Backfill is the same material as bedding
EXCAVATION
The site has been excavated deep enough to enable 1 foot of Backfill has been placed along sides of tank to ensure
compacted clean sand or gravel to act as bedding material full support along the tank’s bottom quadrant
between native soil and tank when anchoring is not required
PIPE CONNECTIONS
Burial depths meet minimum code requirements Electrical isolation of flanged connections has been
(such as NFPA 30). verified with a continuity tester.
Prior to backfilling over tank top, but after piping
NOTE: Check with tank manufacturer when burial depth to the tank, electrical isolation of tank from all
exceeds 5 feet. Steel thickness can be calculated for the equipment has been verified.
required burial depth. No continuity shall be present.

TESTING TANK MONITORING

The tank has been air-tested at 5 psig (kPa) while applying The cathodic protection monitoring station has been
soap solution onto weld seams and fittings to check or leaks installed and brought to grade and access to the soil
OR above the tank has been provided
A vacuum test has been performed in accordance
with the fabricator’s instructions Verify operation of the cathodic protection system by:
A tank to soil potential reading obtained with a high
All local and state testing requirements have been performed impedance voltmeter and a copper/copper sulfate reference
electrode installed with the tank or placed immediately
ANCHORING (check one) above the tank in soil.
Not applicable to this site Record reading: mV
Deadman anchors used
Concrete pad The tank owner has received the above information
Soil and pavement overburden will hold down tank
(Reference PEI/RP 100) All other facets of tank installation have been made in
accordance with sti-P3® instructions
When anchoring with a concrete hold down pad, a minimum
6 inch (152.4 mm) layer of pea over the concrete pad
dimensions to separate tank from pad
Signature and Title of Installing Foreman and/or Project Engineer
When deadman anchors or hold down pads are used, hold down
straps have been separated from the tank by an inert insulating
dielectric material at least 1 inch (25.4 mm) wider than the steel hold
down straps
Signature and Title of Installing Contract

Note: This checklist includes certain key steps in the proper installation of the sti-P3 tank and is intended only as an aid to tank installers who
are knowledgeable and experienced in underground tank installation. Compliance herewith does not necessarily meet the requirements of
all applicable federal, state, and local laws, regulations and ordinances concerning tank installation.

944 Donata Court Lake Zurich IL 60047 l Phone: 847-438-8265 l Fax: 847-438-8766 l www.steeltank.com