Field of the Invention
[0001]The present invention relates to a construction method of corrugated
steel sheets and corrugated steel tanks, more specifically to Fusion Bond
5 Resicoat Epoxy coated corrugated mild steel sheets that can be fabricated
further to form a corrugated steel tank structure.
Background of the Invention
[0002]The Plain mild steel (MS) are commonly used for structural build
10 applications and are also used in the shipping industry and offshore
equipment. Mild Steel plates are broad and generic forms of steel that come
in the form of a plate. The most known application of these steel sheets in
household or industry is construction of tanks for storage of raw water, solid
or liquid effluents.
15
[0003]The most common problems encountered in the tanks constructed
with plain steel sheets is that the thickness of the steel sheets must be more
than 2.5mm. Also, there is a scope of bulging due to heavy load in the upper
rings due to thickness constraint. Further if thickness is lower than 3mm then
20 curving of such sheets is a tedious task.
[0004]These plain steel sheets are prone to rust in a short span of time
depending upon the environment conditions. To avoid rusting, MS
sheets/tanks or other products manufactured with MS sheets are painted by
25 synthetic enamel or any other acid/alkali resistant paint depending upon the
environment requirement. These paints also have a life of maximum a year
or so depending upon the environment conditions prevailing in the area.
Lately the tanks have been painted with simple epoxy paint. The tanks
fabricated from plain MS sheets when used for storage of liquid or any solid
3
or granular products, the height of tanks goes very high and have tendency to
get bulged. To avoid bulging of tanks made from plain MS sheets, the
thickness of the plain MS sheet metal has to be increased tremendously which
become a costly affair.
5
[0005]Further, to paint such huge tanks/other MS sheet products from
outside frequently, is very cumbersome and to repaint the inner surface of
such huge tank or other MS sheet fabricated products is much more
cumbersome, costly, hazardous to environment and labor is involved in the
10 work. Apart from that, emptying the tanks & repainting requires a huge shut
down of the operation of tanks or such products which can cause adverse
effect on the production/utility of such products.
[0006]Further limitations and disadvantages of conventional and traditional
15 approaches will become apparent to one of skill in the art through comparison
of described systems with some aspects of the present disclosure, as set forth
in the remainder of the present application and with reference to the
drawings.
20 Summary of the invention
[0007]The following presents a simplified summary of the disclosure in
order to provide a basic understanding to the reader. This summary is not an
extensive overview of the disclosure and it does not identify key/critical
elements of the invention or delineate the scope of the invention. Its sole
25 purpose is to present some concepts disclosed herein in a simplified form as
a prelude to the more detailed description that is presented later.
[0008]It is an object of the present invention to provide construction method
of Fusion Bond Resicoat epoxy coated corrugated mild steel (MS) sheets
4
which can be further fabricated into Fusion Bond Resicoat Epoxy coated
corrugated MS tanks.
[0009]It is yet another object to provide construction of Fusion Bond
5 Resicoat epoxy coated corrugated mild steel (MS) strips which are structured
as films with less surface area than the sheets.
[0010]It is yet another object to provide corrugated MS tanks having more
stiffness, more sagging resistance, extra bending strength, rigidity along the
10 entire length of the corrugations to avoid any bulging and light weighted over
conventional Plain MS Sheet tanks.
[0011] It is yet another object to produce corrugated MS sheets that
can easily attain curved shape during curving process and that curving process is
15 smoothly followed while maintaining the min. thicknesses of the sheet as per load bearing capacity
required.
[0012]It is yet another object to produce corrugated MS sheets that have
corrosion resistance to withstand the paint for more than 30 years thus
20 eliminating the need of repainting them frequently. Even after long duration
above 30 years the maintenance cost is very low as compared to other sheets
such as ZA/GI sheets.
[0013]It is yet another object to provide corrugated MS tanks that can be
25 customized in size and height as per the need.
[0014]It is yet another object to install PVC Liner inside the corrugated tank,
that is Polyvinyl chloride which is a synthetic plastic polymer, which can be
food grade as well for safety, which actually stores the water inside the tank.
5
this eliminates water proofing inside the tank walls unlike conventional RCC
tanks.
[0015]In an aspect of the present invention, the corrugated MS sheets are
5 coated with Fusion Bond Resicoat Epoxy coating and the construction
method comprises steps of raw material selection and procurement;
segregation according to sheet thickness, corrugations & shearing/cutting of
sheets; drilling/punching holes; bending/curving as per requirement; cleaning
of sheets; surface preparation & shot blasting; final cleaning and inspection;
10 coating with Fusion Bond Resicoat Epoxy(FBE); drying and baking the
sheets and packing of FBE coated sheets.
[0016]In accordance with the present construction method of the FBE coated
corrugated sheets, the holes are drilled on the corrugated MS sheets in stack
15 by using CNC drilling machine prior to fusion bond epoxy application. This
drilling method overcome the issues like bending of sheets during drilling,
less accurate holes and shearing of the fusion bond epoxy lining at the drilled
site where the hole area is prone to rust.
20 [0017]In accordance with the present construction method of corrugation of
MS sheets, the drilling holes, bending the corrugated MS sheets, fusion bond
epoxy coating are applied on the said corrugated MS sheets at factory
premises prior to dispatch for fabrication of tanks at remote site. The tanks
fabricated from fusion bond epoxy coated corrugated MS sheets also provide
25 high resistance from bulging.
[0018]In accordance with the present invention to fabricate corrugated MS
tanks, the corrugated MS sheets are curved or bended based on the diameter
of the tank required and such curved sheets are assembled and fixated using
6
bolts and nuts at remote site. The corrugated MS sheets are drilled with holes
in accordance to AWWD 103 + Indian Standards to increase joint holding
strength combinations through bolting process to form a structure. For tanks,
after the assembling of the sheets is completed, a PVC liner is applied on the
5 inner surface of the tank to retain the contents in the tank and to avoid any
leakage from the tank.
Brief description of the drawings
[0019]These features and advantages of the present disclosure may be
appreciated by reviewing the following description of the present disclosure,
10 along with the accompanying figures wherein like reference numerals refer
to like parts.
[0020]The accompanying drawings illustrate the embodiments of systems,
methods, and other aspects of the disclosure. Any person with ordinary skills
15 in the art will appreciate that the illustrated element boundaries (e.g., boxes,
groups of boxes, or other shapes) in the figures represent an example of the
boundaries. In some examples, one element may be designed as multiple
elements, or multiple elements may be designed as one element. In some
examples, an element shown as an internal component of one element may
20 be implemented as an external component in another and vice versa.
Furthermore, the elements may not be drawn to scale.
[0021]Various embodiments will hereinafter be described in accordance
with the appended drawings, which are provided to illustrate, not limit, the
25 scope, wherein similar designations denote similar elements, and in which:
[0022]Fig 1 depicts the construction method of corrugated MS sheets in
accordance with the present invention.
7
[0023]Fig 2 depicts the fabrication process of corrugated MS tanks in
accordance with the present invention.
[0024]Fig 3(a) is the schematic representation of a decoiler and a corrugation
5 & shearing machine, 3(b) is the corrugation and shearing machine at the
factory site and 3(c) is the corrugated steel sheet produced in accordance with
the present invention.
[0025]Fig 4(a) is the CNC drilling machine for drilling holes in the
10 corrugated sheets and 4(b) is the drilled corrugated sheet with multiple holes
in accordance with the present invention.
[0026]Fig 5 depicts the curved corrugated sheets in accordance with the
present invention.
15
[0027]Fig 6 is the surface blasting machine to get desired- cleaned and rough
surface of the corrugated sheet in accordance with the present invention.
[0028]Fig 7 depicts the process of Fusion Bond Resicoat Epoxy coating on
20 the prepared curved and corrugated sheets as well as the process of cooling
down of the sheets at room temperature, in accordance with the present
invention.
[0029]Fig 8 depicts the assembly of multiple curved and corrugated sheets
25 to form a structure like a storage tank in accordance with the present
invention.
[0030]Fig 9 depicts the inclusion of PVC liner on the inner surface of the
assembled tank structure in accordance with the present invention.
30
8
Description of the invention
[0031]The present disclosure is best understood with reference to the detailed
figures and description set forth herein. Various embodiments have been
discussed with reference to the figures. However, those skilled in the art will
5 readily appreciate that the detailed descriptions provided herein with respect
to the figures are merely for explanatory purposes, as the methods and
systems may extend beyond the described embodiments. As used in the
description herein and throughout the claims that follow, the meaning of “a,”
“an,” and “the” includes plural reference unless the context dictates
10 otherwise. Also, as used in the description herein, the meaning of “in”
includes “in” and “on” unless the context dictates otherwise.
[0032]References to “one embodiment,” “at least one embodiment,” “an
embodiment,” “one example,” “an example,” “for example,” and so on
15 indicate that the embodiment(s) or example(s) may include a particular
feature, structure, characteristic, property, element, or limitation but that not
every embodiment or example necessarily includes that particular feature,
structure, characteristic, property, element, or limitation. Further, repeated
use of the phrase “in an embodiment” does not necessarily refer to the same
20 embodiment.
[0033]Methods of the present invention may be implemented by performing
or completing manually, automatically, or a combination thereof, selected
steps or tasks. The term “method” refers to manners, means, techniques and
25 procedures for accomplishing a given task including, but not limited to, those
manners, means, techniques, and procedures either known to, or readily
developed from known manners, means, techniques and procedures by
practitioners of the art to which the invention belongs. The descriptions,
examples, methods, and materials presented in the claims and the
9
specification are not to be construed as limiting but rather as illustrative only.
Those skilled in the art will envision many other possible variations within
the scope of the technology described herein.
5 [0034]The present invention is related to a construction method of Fusion
Bond Resicoat Epoxy coated corrugated mild steel (MS) sheets which can be
further fabricated into Fusion Bond Resicoat Epoxy coated corrugated MS
tanks. The corrugated MS tanks have more stiffness, more sagging resistance,
extra bending strength, rigidity along the entire length of the corrugations to
10 avoid any bulging and light weighted over conventional Plain MS Sheet
tanks. Further the corrugated MS sheets can easily attain multiple diameters
while maintaining lower thicknesses of sheets and easy maintenance. Further,
the sheets are made of eco-friendly components, and tanks can be easily
relocated, salvage/scrap has value and easy to dismantle if tank is no more
15 required and can be sold at good value as the inside material is preserved.
[0035]In the preferred embodiment of the present invention, the corrugated
MS sheets are coated with Fusion Bond Resicoat Epoxy coating and the
construction method comprises steps of raw material selection and
20 procurement; corrugations & shearing/cutting process; drilling/punching;
bending/curving as per requirement; surface preparation & shot blasting;
final cleaning and inspection; Fusion Bond Resicoat Epoxy(FBE) process
and packing of FBE coated sheets.
25 [0036]In another embodiment, the same method of construction of
corrugated MS sheets can be used for construction of Fusion Bond Resicoat
epoxy coated corrugated mild steel (MS) strips which are structured as films
with less surface area than the sheets.
10
[0037]In accordance with preferred embodiment, the construction method of
the FBE coated corrugated sheets, the holes are drilled on the corrugated MS
sheets in stack by using CNC drilling machine prior to fusion bond epoxy
application. This drilling method overcome the issues like bending of sheets
5 during drilling, less accurate holes and shearing of the fusion bond epoxy
lining at the drilled site where the hole area is prone to rust.
[0038]In accordance with the preferred embodiment, the method of
corrugation of MS sheets, the drilling holes, bending the corrugated MS
10 sheets, fusion bond epoxy coating are applied on the said corrugated MS
sheets at factory premises prior to dispatch for fabrication of tanks at remote
site. The tanks fabricated from fusion bond epoxy coated corrugated MS
sheets also provide high resistance from bulging.
15 [0039]In accordance with the preferred embodiment, the method of
fabrication of corrugated MS tanks, the corrugated MS sheets are curved or
bended based on the diameter of the tank required and such curved sheets are
assembled and fixated using bolts and nuts at remote site. The corrugated MS
sheets are drilled with maximum number of holes to increase the joint holding
20 strength when these sheets are assembled to form a structure. For tanks after
the assembling of the sheets is completed a PVC liner is applied, on the inner
surface of the tank to retain the contents in the tank and to avoid any leakage
from the tank.
25 [0040]Referring to Fig 1 is construction method of FBE coated corrugated
MS sheets which comprises steps of: corrugating the MS coil (101) into
corrugated sheets; drilling multiple holes (102) on the corrugated sheets;
curving the corrugated sheets as per required diameter for a structure like
storage tank (103); surface preparation to achieve desired roughness and
11
cleaned corrugated sheets before FBE coating (104); removing abrasives or
other contaminants on sheets (105); applying FBE coating which further
comprises: pre- heating the corrugated sheet up to 200- 300°C before Fusion
Bond Resicoat Epoxy coating (106); applying FBE coating powder by
5 electrostatic automatic spraying guns uniformly on both sides of sheets to
achieve desired coating thickness (107); and post- heating the sheets inside a
furnace that is maintained at 150°C to 200°C (108); after FBE coating
cooling off the coated corrugated sheets at room temperature (109); and
performing final inspection on the coating thickness and packing the sheets
10 (110).
[0041]Referring to Fig 2 is construction method of FBE coated corrugated
MS tanks which comprises steps of: corrugating the MS coil (201) into
corrugated sheets; drilling multiple holes (202) on the corrugated sheets;
15 curving the corrugated sheets as per required diameter for a structure like
storage tank (203); surface preparation to achieve desired roughness and
cleaned corrugated sheets before FBE coating (204); removing abrasives or
other contaminants on sheets (205); applying FBE coating which further
comprises: pre- heating the corrugated sheet upto 200- 300°C before Fusion
20 Bond Resicoat Epoxy coating (206); applying FBE coating powder by
electrostatic automatic spraying guns uniformly on both sides of sheets to
achieve desired coating thickness (207); and post- heating the sheets inside a
furnace that is maintained at 150°C to 200°C (208); after FBE coating
cooling off the coated corrugated sheets at room temperature (209);
25 performing final inspection on the coating thickness and packing the sheets,
nuts- bolts and PVC liners for fabrication of desired structures (210);
assembling the sheets by nut-bolting to form the desired structure (211) and
applying PVC liner on the inner surface of the structure to retain the contents
12
inside such structure (212) and avoid leakage of the contents stored in the
structure. The structures can be used as water storage tanks, in Effluent
Treatment Plants, in Sewage Treatment Plants, in Wastewater Treatment
Plants, for Fire/Raw/Clear water Storage.
5
[0042]Referring to Fig 3 is the construction of corrugated MS sheets using a
corrugation and shearing machine as shown in Fig 3(b). The MS Coil is
loaded on decoiler (311). The decoiler (311) feeds the strip/sheet to special
purpose corrugation and shearing machine (312) bed where these strip gets
10 corrugated (300) (as shown in Fig 3(c)). The special purpose corrugation and
shearing machine (312) consists of multiple rollers (313), fixed at certain
distance that can be adjusted in vertical direction to get required depth of
Pitch & corrugation for the MS sheets. The rollers (313) have sinusoidal
periphery. Number of Corrugations (301) increase on roller from starting to
15 end to provide sinusoidal corrugated profile to sheets then these sheets are
sheared by automatic hydraulic cutter (314) placed at end of corrugation
machine (312) as per size requirement. After cutting, the corrugated sheets
are passed over an exit belt/surface (315).
20 [0043]After the corrugated sheet are produced, using special purpose CNC
drilling machine (as shown in Fig 4(a)) wherein the holes are drilled
accurately on stack of corrugated sheets (as shown in Fig 4(b)). The tank is
formed by assembling multiple curved corrugated sheets through nut-bolting
to each other through the drilled holes. Punching/drilling multiple holes on
25 sinusoidal shaped corrugated profile sheet is difficult task to perform with
accuracy. Orientation/Centre distance of holes on sheets should be strictly as
per drawing & have very precise tolerances. Otherwise, the holes of the
adjoining sheets will not match with each other & the sheets cannot be joined
precisely at the remote site thus this a prominent step in the present invention.
13
[0044]After drilling holes on the corrugated sheets (300), the drilled
corrugated sheets (Fig 4(b)) are then curved on special curving machine as
per required diameter of the tank or any other structure where these sheets
5 are used. Rollers of curving machine have sinusoidal corrugated profile to
match with the required sheet profile. Fig 5 shows the curved corrugated
sheets with multiple holes.
[0045]After the curved corrugated sheets are prepared these sheets undergo
10 surface preparation for Fusion Bond Resicoat Epoxy coating. Prior to shot
blast cleaning, the corrugated sheets are inspected and pre-cleaned to remove
all oil, grease, mud, loosely adhering deposits on both surfaces of the sheet
and then the sheets are washed through spray gun by alkaline based
degreasing chemicals. The corrugated sheets on both surfaces are cleaned by
15 blast cleaning to near-white metal in accordance with SSPC-SP10. The Shot
blasting process is performed by special purpose blasting machine (as shown
in Fig 6) to get desired surface roughness. This machine has total 4
centrifugal blast wheels. 2 wheels (601) on upside surface of corrugated sheet
& opposite to each other & 2 wheels (602) on downside surface of corrugated
20 sheet & opposite to each other. To cover full section of sheet from both side,
blast wheels rotate at very high speed projecting steel grits to sheet surface.
After Blasting, surface roughness is checked by roughness tester. After
passing all cleaning stages then sheets proceed for Fusion Bond Epoxy (FBE)
coating process. Expanded blasting media debris and dust is removed from
25 blasted surfaces prior to application of the fusion-bonded epoxy powder
coating, raised slivers, scabs, laps, sharp edges, or seams shall be removed
using abrasive grinders from surface.
14
[0046]Prior to coating, the cleaned sheets are inspected to ensure that all
cleaning procedures have been appropriately performed. The abrasives or
other contaminants on sheets shall be removed. Blast cleaned corrugated
sheet shall be protected from conditions that would allow those to be rusted
5 or damaged before coating.
[0047]After cleaning of the surface and desired roughness of the corrugated
sheet is achieved, the cleaned corrugated sheets are loaded/hanged on
conveyor which passes through furnaces for Fusion Bond Resicoat
10 Epoxy(FBE) coating. The conveyor timing is adjusted as per sheet thickness,
coating thickness requirement.
[0048]The FBE coating comprises the following steps of pre-heating, FBE
powder coating and post heating of the coated corrugated sheets. The sheets
15 are pre- heated up to reach the appropriate application temperature 200-
300°C uniform metal temperature at the specified levels is maintained (as
shown in Fig 7(a)). The Pre-heat temperature is monitored, controlled and
recorded to achieve the perfect Fusion Bond Resicoat Epoxy (FBE) coating.
It is ensured that both the surfaces are completely cleaned and dried. Now
20 sheets are passed through special designed furnace where desired
temperature (i.e. 200- 300°C on metal) is achieved & temperature is verified
by infrared thermometers. Application of FBE coating powder by
electrostatic automatic spraying guns is uniformly spread on both sides of
sheets to achieve desired coating thickness (as shown in Fig 7(b)). The epoxy
25 powder is kept on both sides of the sheets by proper electrostatic charge on
the sheets to maintain the uniform power thickness on both sides of the
sheets. The spraying guns are positioned appropriately in the coating
chamber to give a uniform powder deposition. The spraying guns are
positioned at a distance of 200 mm from the steel material. Then adjustment
15
is done according to epoxy coating film thickness requirements. After, the
coating is completed, again the sheets are passed through furnace where
temperature on metal inside furnace is maintained at 150°C to 200°C.
Through this entire process, the fusion bonding of the epoxy coating on MS
5 corrugated sheets gives a life of 30+ years to epoxy coating on the MS
corrugated sheets. After that material is naturally cooled down to ambient
temperature (as shown in Fig 7(c)).
[0049]After completion of the coating and cooling off process, the FBE
10 coated sheets are again inspected by using the calibrated holiday detector to
detect any discontinuity in coating. After complete inspection and
examination, FBE coated sheets are packed in mild steel structured with
wooden board covered boxes each sheet separated by cardboard.
15 [0050]In accordance with another embodiment of the present invention, after
complete inspection and examination, FBE coated corrugated MS sheets are
are packed in mild steel structured with wooden board covered boxes each
sheet separated by cardboard. Other material like liners, nut & bolts are
dispatched as required for assembling the desired structure at remote site.
20
[0051]Further, on receipt of the entire material including Fusion Bond
Resicoat Epoxy coated MS corrugated sheets including PVC liners and all
other related material like nuts & bolts at site, the Fusion Bond Resicoat
Epoxy coated MS corrugated sheets are assembled (as shown in Fig 8), nut
25 & bolted through the holes provided on both ends of the sheets with due care.
The bottom and roof of the tanks are also fabricated as shown in Fig 8. After
the tank is ready, the PVC liner is fixed as per the requirement.
16
[0052]The liner (901) is covered all over the inner surface of the corrugated
tank walls (902) extending from the top portion (905). The PVC liner (901)
is supported by a liner flap (903) such that the PVC liner (901) is intact with
the corrugated wall (902). The bottom portion of the tank (906) is layered
5 with geotextile (904) of about 3mm thickness to prevent direct contact from
foundation & ensure safety of liner from below.
[0053]In accordance with the present invention the corrugated tanks and
other structures using the corrugated sheets are manufactured in accordance
10 with National & International standard which make it sustainable in adverse
environmental condition such as Storms & earthquake. The advantages of the
corrugated sheets constructed by the present method are:
• Adaptation of special corrugation technology on the MS sheets which
provide more stiffness & strength to sheet with less thickness.
15 • Corrugated profile sheets are curved easily & retain that curviness.
• Corrugated sheets are light in weight & have rigidity along the entire
length of the corrugations thus no chance of bulging.
• Performing 100% inspection on Fusion Bond Resicoat Epoxy coated
MS corrugated sheets with latest non-destructive testing technique
20 which provide excellent corrosion resistance.
Further, the advantages of the corrugated structures like tanks that are
constructed by the present method are:
• No welding work required while installation which make its
economical, time-cost saving of project & eco-friendly.
25 • corrugated tanks are lighter in weight & supplied in dismantled
condition which make transportation easy & economical.
• Corrugated tanks are easy to relocate/reusable.
17
• Tanks are installed with PVC Liner inside the corrugated tank, that is
Polyvinyl chloride which is a synthetic plastic polymer, which can be
food grade as well for safety, which actually stores the water inside
the tank.
5 • water proofing inside the tank walls is not requires unlike
conventional RCC tanks.
• tanks can be easily relocated,
• salvage/scrap has value
• easy to dismantle if tank is no more required and can be sold at good
10 value as the inside material is preserved.
[0054]No language in the specification should be construed as indicating any
non-claimed element as essential to the practice of the invention.
15 [0055]It will be apparent to those skilled in the art that various modifications
and variations can be made to the present invention without departing from
the scope of the invention. There is no intention to limit the invention to the
specific form or forms enclosed. On the contrary, the intention is to cover all
modifications, alternative constructions, and equivalents falling within the
20 scope of the invention, as defined in the appended claims. Thus, it is intended
that the present invention cover the modifications and variations of this
invention, provided they are within the scope of the appended claims and
their equivalents.

CLAIMS:
We claim:
1. A construction method of Fusion Bond Resicoat Epoxy(FBE) coated
5 corrugated mild steel (MS) sheets, such method comprising steps of:
a. corrugating the MS coil (101) into corrugated sheets (300);
b. drilling multiple holes (102) on the corrugated sheets (300);
c. curving the corrugated sheets as per required diameter for a
structure like storage tank (103);
10 d. surface preparation to achieve desired roughness and cleaned
corrugated sheets before FBE coating (104);
e. removing abrasives or other contaminants on sheets (105);
f. applying FBE coating which further comprises:
i. pre- heating the corrugated sheet surface upto 200°C -
15 300°C before Fusion Bond Resicoat Epoxy coating
(106);
ii. applying FBE coating powder by electrostatic automatic
spraying guns uniformly on both sides of sheets to
achieve desired coating thickness (107);
20 iii. post- heating the sheets inside a furnace that is
maintained at 150°C to 200°C (108);
g. cooling off the coated corrugated sheets at room temperature
(109); and
h. performing final inspection on the coating thickness and
25 packing the sheets (110).
2. The construction method as claimed in claim 1 wherein, the
corrugated sheets (300) are generated by a special purpose corrugation
and shearing machine (312) consisting of multiple rollers (313), fixed
19
at certain distance that can be adjusted in vertical direction to get
required depth of Pitch & corrugation for the MS sheets.
3. The construction method as claimed in claim 1 wherein, drilling
multiple holes (102) on the corrugated sheets (300) is achieved using
5 special purpose CNC drilling machine.
4. The construction method as claimed in claim 1 wherein, drilling
multiple holes (102) on the corrugated sheets (300) increases the jointholding strength when assembling multiple corrugated sheets.
5. A construction method of Fusion Bond Resicoat Epoxy(FBE) coated
10 corrugated mild steel (MS) structures, such method comprising steps
of:
a. corrugating the MS coil (101) into corrugated sheets (300);
b. drilling multiple holes (102) on the corrugated sheets (300);
c. curving the corrugated sheets as per required diameter for a
15 structure like storage tank (203);
d. surface preparation to achieve desired roughness and cleaned
corrugated sheets before FBE coating (204);
e. removing abrasives or other contaminants on sheets (205);
f. applying FBE coating which further comprises:
20 i. pre- heating the corrugated sheet surface upto 200-
300°C before Fusion Bond Resicoat Epoxy coating
(206);
ii. applying FBE coating powder by electrostatic automatic
spraying guns uniformly on both sides of sheets to
25 achieve desired coating thickness (207);
iii. post- heating the sheets inside a furnace that is
maintained at 150°C to 200°C (208);
g. cooling off the coated corrugated sheets at room temperature
(209);
20
h. performing final inspection on the coating thickness and
packing the sheets, nuts- bolts and PVC liners for fabrication
of the structures (210);
i. assembling the sheets by nut-bolting to form the structure
5 (211); and
j. applying PVC liner on the inner surface of the structure to
retain the contents inside such structure (212) and avoid
leakage of the contents stored in the structure.
6. The construction method as claimed in claim 5 wherein, the
10 corrugated sheets (300) are generated by a special purpose corrugation
and shearing machine (312) consisting of multiple rollers (313), fixed
at certain distance that can be adjusted in vertical direction to get
required depth of Pitch & corrugation for the MS sheets.
7. The construction method as claimed in claim 5 wherein, drilling
15 multiple holes (202) on the corrugated sheets (300) is achieved using
special purpose CNC drilling machine.
8. The construction method as claimed in claim 5 wherein, drilling
multiple holes (202) on the corrugated sheets (300) increases the jointholding strength when assembling multiple corrugated sheets.
20 9. The construction method as claimed in claim 5 wherein, the structure
constructed is used as water storage tanks, in Effluent Treatment
Plants, in Sewage Treatment Plants, in Wastewater Treatment Plants,
for Fire water Storage.