End-to-end storage tank manufacturing and construction under one contract
Building a large above-ground storage tank is not a single job — it is a coordinated sequence of civil, mechanical, NDT, painting and instrumentation work carried out to a code. As a full-service storage tank manufacturer, HAIL delivers every step in-house: site survey, ring wall foundation, plate procurement to MTC (Material Test Certificate), shop fabrication, field erection by jacking-up or jacking-down method, weld qualification (WPS/PQR), 100% radiography on shell joints, hydrotesting, settlement survey, internal/external lining, calibration and final handover. One manufacturer, one contract, one schedule.
Whether you are commissioning a 70,000 KL crude oil tank at a refinery or a 250 KL transmix tank at a depot, the same engineering rigour applies. Our leadership team has built more than 2,000 storage tanks across India and 8 overseas markets, including a single project of 11 crude oil tanks (70,000 KL each) and a 1.38 million KL terminal.
Tank types we build
Cone Roof Tanks
Fixed cone-roof atmospheric tanks for diesel, kerosene, water, chemicals and other low-vapour-pressure products. Self-supporting or column-supported roofs to API 650 Appendix F.
External Floating Roof (EFR)
Single-deck and double-deck pontoon roofs for crude oil, motor spirit, naphtha and other volatile fuels. Pan-type and pontoon-type designs with primary and secondary seals to API 650 Appendix C.
Internal Floating Roof (IFR)
Aluminium honeycomb and skin-and-pontoon IFRs inside fixed-roof tanks — vapour control with weather protection. Suitable for ATF, MS, naphtha and product retail terminals.
DDFR (Double Deck Floating Roof)
Buoyant double-deck roofs for very large diameter crude tanks. Higher rigidity, better stability in wind and rainfall, lower seal wear over a 25-year service life.
Chemical Storage Tanks
Tanks for phosphoric acid, sulphuric acid, HCl, caustic soda, methanol, ethanol, solvents and specialty chemicals. Rubber-lined, FRP-lined, epoxy-novolac or SS 316/duplex construction based on corrosion profile.
Ammonia & Cryogenic Tanks
Double-wall cryogenic tanks to API 620 / BS 7777 for anhydrous ammonia (−33 °C), LPG (−42 °C), liquid oxygen, liquid nitrogen, ethylene and propylene. LTCS inner shell with carbon steel outer.
Industrial Silos
Design and construction of industrial silos for storage of cement, fertilizers, chemicals, and food grains. Fabrication in carbon steel and stainless steel per industrial standards.
Specialty & Lined Tanks
Fire-water tanks (NFPA), DM-water tanks, FRP-lined acid tanks, rubber-lined chemical tanks and stainless-steel/duplex storage for aggressive service.
Standards, codes and quality
- Design & construction: API 650, API 620, IS 803, BS 7777, OISD-244.
- In-service inspection & repair: API 653 fitness-for-service evaluation, bottom plate replacement, shell ring replacement, settlement survey.
- Welding: ASME Section IX qualified WPS/PQR for SMAW, GMAW, GTAW and SAW. All welders pre-qualified to procedure.
- NDT: 100% RT on vertical shell seams, MT/PT on critical attachment welds, vacuum-box test on bottom welds, helium leak test on cryogenic tanks.
- Hydrotest & settlement: Phased filling with elevation survey at 25 / 50 / 75 / 100% to detect differential settlement.
- Coatings: SA 2.5 surface preparation, internal lining (epoxy, novolac, rubber) and external systems (zinc-rich primer + epoxy + polyurethane) per NACE/SSPC.
Reference projects
| Project | Scope | Client |
|---|---|---|
| IOCL Petroleum Terminal — Amlekhgunj, Nepal | 2 × 4,100 KL IFR product tanks, 2 × 250 KL transmix tanks, 2 × 3,000 KL water tanks; structural, piping (3LPE), painting | Likitha Infrastructure Ltd. |
| Crude oil tank farm — Refinery | 11 × 70,000 KL crude oil tanks; total 1.38 million KL storage | Leadership-led project |
| IOCL Barauni Refinery (Coker-B Revamp) | Tankage, piping, painting, E&I, civil — multi-discipline EPCC | UPS Constructions Pvt. Ltd. |
| Phosphoric Acid Storage Tank — Jhabua, MP | 19.5 m × 12.6 m chemical storage tank, RCC pad, civil & lining | Krishna Phoschem Ltd. |
Products we store — oil, chemical, ammonia & more
Petroleum & fuel: Crude oil, petrol (MS), high-speed diesel (HSD), light diesel oil (LDO), aviation turbine fuel (ATF), kerosene (SKO), naphtha, furnace oil (FO), lube oil, base oil, bitumen, gasoline, ethanol-blended fuels and biodiesel.
Chemical & acid: Phosphoric acid, sulphuric acid, hydrochloric acid, caustic soda (NaOH), methanol, ethanol, solvents, alkalis and specialty chemicals in SS 316, duplex, rubber-lined or FRP-lined tanks.
Ammonia & cryogenic: Anhydrous ammonia (−33 °C), LPG (−42 °C), liquid oxygen, liquid nitrogen, ethylene, propylene and butene in double-wall cryogenic tanks to API 620 / BS 7777.
Water & utility: Fire water (NFPA), raw water, demineralised (DM) water, cooling water, effluent and process water.
Others: Edible oils, palm oil, molasses, fertilizer intermediates, cement (silos), fly ash, food grains and any bulk liquid or granular material requiring engineered storage.
Why clients choose HAIL for storage tanks
- Leadership team with management expertise of 2,000+ tanks and 300+ projects across India and 8 overseas markets.
- Owned 33,000 sq.ft. fabrication workshop at Kalol, Gujarat — pre-fabricated shells and components reduce site cycle time.
- Owned crane fleet (200 MT, 100 MT, 50 MT, 20 MT) eliminates rental dependencies.
- Consortium with RINA Consulting S.p.A. for third-party design review and certification.
- WPS/PQR-qualified welders, in-house DPT, pneumatic and hydrostatic testing.
- HSE record of zero major incidents inside live refineries (IOCL Barauni, IOCL Gujarat, Birla Copper Dahej).
The 12-step storage tank construction process
Every API 650 storage tank project at HAIL follows the same engineered sequence — refined over 2,000+ tanks. The depth of this process is what separates a tank that performs for 25 years from one that fails fitness-for-service in five.
- Site survey & soil report. Geotechnical investigation, plot plan, prevailing wind direction, fire-radiation distance check per OISD-244, foundation type selection (RCC raft, ring beam or pile cap).
- Basis-of-design (BOD) & engineering. Tank diameter, height, capacity, design temperature, product specific gravity, seismic zone (IS 1893), wind speed (IS 875). Roof type selection — cone, IFR, EFR, DDFR, dome or double-wall cryogenic.
- Mechanical design & shell calculation. Shell-course thicknesses per API 650 1-foot or variable-design-point method. Bottom-plate sketch layout. Wind-girder and intermediate-stiffener sizing. Anchor-chair design for seismic uplift.
- Plate procurement to MTC. SA 516 Gr.70 / IS 2062 Gr. B carbon steel — every plate with mill test certificate, PMI verification at workshop receipt, and ultrasonic lamination check on plates above 12 mm.
- Welding qualification (WPS/PQR). Each weld procedure qualified to ASME Section IX with hot-pass, fill and cap qualifications. Welders pre-qualified on test coupons before mobilisation.
- RCC ring-wall foundation. Excavation, lean concrete, reinforcement, formwork, M30 concrete pour, 28-day cure, dimensional and elevation survey, ring-wall handover.
- Bottom plate laying & welding. Sketch plate first (lap-welded), then annular plates (butt-welded with full RT), then sub-bottom course. Vacuum-box test on every bottom weld for leak tightness.
- Shell erection — jack-up method. Top course assembled at ground level on the bottom plate. Pneumatic jacks lift the full ring 2.4 m. Next course welded underneath. Repeat ring-by-ring upwards. Hydraulic jacking-down method used on cryogenic and double-wall tanks.
- Roof construction. Cone roof: rafters + structural ring + roof plates (frangible joint). EFR/IFR: pontoon assembly, deck plate welding, primary and secondary seals. DDFR: upper and lower deck buoyancy compartments.
- NDT inspection. 100% radiography on Category A & B shell seams. Magnetic particle test (MT) on attachment welds. Penetrant test (PT) on stainless welds. Vacuum-box on all bottom welds. Helium leak test on cryogenic annular space.
- Hydrotest & settlement survey. Phased water filling at 25 / 50 / 75 / 100 % with elevation survey at 8 cardinal points to detect differential settlement. Floating-roof seal & buoyancy test. Drain and dry.
- Internal lining, painting, calibration & handover. SA 2.5 surface preparation, internal lining (epoxy / novolac / rubber as per service), external paint system (zinc-rich primer + epoxy + polyurethane), tank calibration certificate, full data dossier handover.
Tank size & capacity guide
HAIL's leadership has executed tanks across the full range — from 250 KL transmix tanks at oil depots to 70,000 KL crude oil tanks at refineries. Pricing depends on diameter, height, plate thickness, roof type, lining and site logistics, but the table below gives indicative ranges.
| Capacity | Typical diameter × height | Common service | Typical lead time |
|---|---|---|---|
| 250 — 1,000 KL | 8—12 m × 6—10 m | Transmix, slop, additive, fire water | 10—14 weeks |
| 1,000 — 5,000 KL | 14—22 m × 10—14 m | HSD, MS, kerosene at depots | 14—22 weeks |
| 5,000 — 15,000 KL | 22—32 m × 12—16 m | Naphtha, ATF, lube oil, edible oils | 22—32 weeks |
| 15,000 — 35,000 KL | 32—50 m × 14—18 m | Crude product, large depot tanks | 32—46 weeks |
| 35,000 — 70,000 KL | 50—80 m × 18—22 m | Refinery crude oil storage | 46—66 weeks |
| 70,000 — 1,50,000 KL | 80—110 m × 18—24 m | Crude tank farms, mega-terminals | 66—90 weeks |
Materials & metallurgy
The metallurgy choice is set by the product, temperature, corrosion rate and statutory standard. HAIL works in every common (and several uncommon) plate material for storage tank construction:
| Material | Specification | Typical use |
|---|---|---|
| Carbon steel | SA 516 Gr. 60/65/70, IS 2062 Gr. B/E | Petrol, diesel, crude oil, water — most common |
| Low-temp carbon steel (LTCS) | SA 333 Gr. 6, SA 350 LF2 | Refrigerated LPG, ammonia (-33 ×C), butene |
| 9% Nickel steel | SA 553 Type I | LNG (-162 ×C), liquid ethylene |
| Stainless steel 304/304L | SA 240 | Demineralised water, food-grade, mild chemicals |
| Stainless steel 316/316L | SA 240 | Phosphoric acid, pharma intermediates, sea water |
| Stainless steel 321 | SA 240 | Furnace oil at elevated temperature |
| Duplex 2205 / 2507 | SA 240 UNS S31803/S32750 | Aggressive chlorides, brackish water, urea |
| Rubber-lined CS | SA 516 + Hypalon/Butyl/Neoprene | Hydrochloric acid, sulphuric acid (dilute) |
| FRP-lined CS | SA 516 + glass-fibre vinyl ester | Concentrated acids, alkalis, solvents |
Storage tank standards — which one applies?
India follows three primary standards for atmospheric storage tanks. The choice depends on product, pressure, temperature and statutory framework:
| Standard | Scope | Pressure | Temperature | Typical India use |
|---|---|---|---|---|
| API 650 | Welded steel tanks for oil storage | Atmospheric to 18 kPa | —40 to +90 ×C (basic), Appendix S for higher | Refineries, petroleum terminals — IOCL, BPCL, HPCL, Reliance, Nayara |
| IS 803 | Indian standard for vertical mild-steel oil tanks | Atmospheric | Ambient | Indian Railways, smaller depots, water utilities |
| API 620 | Low-pressure storage (refrigerated & hot service) | Up to 100 kPa | —196 to +120 ×C (Appendices Q, R, S) | Cryogenic ammonia, LPG, LNG, ethylene |
| BS 7777 | Flat-bottomed cryogenic tanks | Atmospheric / low-pressure | —196 to +90 ×C | LNG, LIN, LOX (often used alongside EN 14620) |
| API 653 | In-service inspection, repair, alteration & reconstruction | — | — | Aged tank fitness-for-service, bottom replacement, shell ring repair |
HAIL designs and constructs to all four primary standards plus the Indian statutory framework: OISD-244 (terminal layout), OISD-118 (LPG storage), OISD-117 (fire-water), SMPV(U) Rules 2016 (pressure vessels) and PESO licensing.
Storage tank cost guide — what drives the price
A common question from procurement teams: what does a storage tank cost? The honest answer: it depends on six variables. Below is the relative cost-driver weighting from our 2,000-tank reference database:
- Diameter (35—45% of cost) — plate weight scales with diameter squared. A 60 m tank uses ~4× the plate of a 30 m tank.
- Height (15—20%) — drives shell-course thicknesses (lower courses thicker for hydrostatic head).
- Roof type (10—15%) — DDFR is the most expensive (double-deck buoyancy + two seals); cone roof is the cheapest.
- Metallurgy (5—25%) — SS 304 ~3× CS, SS 316 ~4× CS, 9% Ni ~5× CS, duplex ~3.5× CS.
- Lining & coating (3—10%) — rubber lining adds 5—8% to a CS acid tank; FRP lining 8—12%.
- Site logistics (2—8%) — remote site = additional crane mobilisation, housing, slower productivity.
For a budgetary indication, send us your tank schedule and we will respond with a cost breakdown and execution plan within one week.
Case study — 27 tanks, 1.38 million KL terminal
Our leadership team's largest single-project execution: a 27-tank petroleum terminal totalling 1.38 million KL of storage. Key parameters:
- 11 × 70,000 KL crude oil tanks — 79 m diameter × 18 m height, EFR with double seal, RCC ring-wall foundation, 32 mm bottom course tapering to 14 mm top course, full radiography on shell verticals.
- 16 × additional product tanks — naphtha, MS, HSD, ATF in IFR/cone-roof construction.
- Total plate quantity: ~22,000 MT carbon steel SA 516 Gr.70.
- Welding: 100,000+ inches of pressure-class weld, 100% RT on shell verticals, ASME Section IX qualified WPS/PQR, 50-welder crew at peak.
- Civil: 27 RCC ring walls + dyke wall + tank pad + foam system + fire-water network.
- Schedule: 32 months from FEED to mechanical completion. Zero LTI (Lost Time Incident).
This single project demonstrates HAIL leadership's ability to scale — from one tank to a 27-tank terminal under one EPCC contract. Same execution rigour. Same QA discipline.
Frequently asked questions
What is the largest storage tank HAIL can build?
Up to 110 metres in diameter. Our leadership has executed 11 crude oil tanks of 70,000 KL each in a single project. Final size is set by your storage capacity, available plot, ring-wall geometry and the applicable code.
Which storage tank standards does HAIL design and build to?
API 650 for atmospheric welded steel tanks, IS 803 for Indian standard vertical mild-steel oil tanks, API 620 for low-pressure storage and BS 7777 for double-wall cryogenic tanks. In-service inspection follows API 653.
Do you build floating-roof tanks for petrol and crude oil?
Yes. We build EFR, IFR and DDFR tanks for crude oil, MS, naphtha, ATF and other volatile petroleum products. Floating-roof design controls vapour loss and meets refinery and terminal emissions requirements.
Do you handle ring-wall foundation and civil work too?
Yes. Turnkey scope includes RCC ring-wall foundation, dyke wall, formwork, earthwork, brickwork, cement grouting, trimix flooring and all associated civil works — same scope we delivered on the Phosphoric Acid tank for Krishna Phoschem.
Do you build storage tanks outside India?
Yes. We have delivered cross-border EPC for the IOCL terminal at Amlekhgunj, Nepal, and we tender for projects in UAE, Oman, Bahrain, Kuwait, Qatar, Indonesia and Malaysia.
How long does it take to build a storage tank?
Typical lead time runs from 10 weeks for a small 250 KL transmix tank up to 90 weeks for a 1,50,000 KL crude tank including foundation, fabrication, erection, hydrotest and commissioning. The bottleneck is usually plate procurement (8—12 weeks for thick CS plate) and ring-wall curing (4 weeks). See the size & capacity table above for indicative ranges.
What is the difference between EFR, IFR, DDFR and Cone Roof tanks?
Cone Roof — fixed sloped roof, cheapest, used for non-volatile products (water, diesel, FO). External Floating Roof (EFR) — open-top tank with a floating deck on the liquid; controls vapour loss for volatile products like crude oil, MS, naphtha. Internal Floating Roof (IFR) — floating deck inside a fixed-roof tank; weather protection plus vapour control for ATF, MS, naphtha. Double Deck Floating Roof (DDFR) — buoyant double-deck open-top roof with upper and lower compartments; used on very large crude oil tanks (60+ m diameter) for rigidity and lower seal wear over 25-year service life.
What is the API 650 standard for?
API 650 is the American Petroleum Institute standard for the design, fabrication, erection, inspection and testing of welded steel tanks for the storage of petroleum, petrochemicals and other liquids at atmospheric pressure. It covers tanks from 6 m to 110 m diameter, with service temperatures from —40 ×C to +90 ×C (Appendix S allows higher). Most refinery and terminal storage in India is built to API 650.
Does HAIL provide tank inspection and API 653 repair services?
Yes. We perform fitness-for-service evaluation, settlement survey, magnetic flux leakage (MFL) bottom scanning, shell thickness ultrasonic survey, bottom plate replacement, shell ring replacement and roof rehabilitation per API 653. We also rebuild storage tanks after major damage or end-of-life.
What is the typical cost of a storage tank in India?
Cost varies widely with size and metallurgy. As a budgetary guide: a 5,000 KL CS cone-roof tank in Gujarat is in the range of —1.5—2.5 Cr; a 30,000 KL EFR crude tank is —8—12 Cr; a 70,000 KL DDFR crude tank is —18—28 Cr. SS 316, duplex, cryogenic and lined tanks command 2—4× premium. Send your tank schedule for a precise quotation.
What is hydrotesting and why is settlement survey critical?
Hydrotest is the controlled water-fill of a newly constructed tank to verify shell strength, weld integrity and bottom-plate leak tightness. Settlement survey at 25%, 50%, 75% and 100% fill measures elevation at 8 cardinal points around the perimeter; differential settlement above tolerance indicates foundation issue and must be corrected before the tank is put into service. We provide full hydrotest charts and settlement records as part of every dossier.
What is the difference between sketch plate and annular plate on a tank bottom?
The bottom of an API 650 tank is built in two layers near the shell. Annular plates are thicker (10—14 mm) ring plates directly under the shell — they take the heaviest load and are butt-welded with full radiography. Sketch plates form the rest of the bottom inside the annular ring — typically 6—8 mm, lap-welded. Both are vacuum-box tested for leak tightness.
Does HAIL provide internal lining for chemical and acid storage tanks?
Yes. We apply rubber linings (Hypalon, Butyl, Neoprene), epoxy linings (novolac for high-temp acids), polyurethane linings, glass-flake epoxy, FRP linings, and metallic clad construction. Lining selection is based on the chemical, concentration, temperature and required service life.
What is OISD-244 and which Indian regulations apply to storage tanks?
OISD-244 is the Oil Industry Safety Directorate code for layout of POL terminals and depots. Other key Indian codes: OISD-118 (LPG installation), OISD-117 (fire-water), OISD-150 (cross-country pipelines), OISD-141 (lightning protection). Statutory licensing comes from PESO (CCOE for petroleum), CCOE for compressed gas, and Factories Act.
Can you build storage tanks for ammonia, LPG and other cryogenic service?
Yes — we design and construct double-wall cryogenic tanks to API 620 Appendix Q/R and BS 7777 for ammonia (-33 ×C), LPG (-42 ×C), liquid oxygen (-183 ×C), liquid nitrogen (-196 ×C), ethylene (-104 ×C), butene and propylene. See our cryogenic tank construction page for details.
Do you handle dyke walls, fire water, foam systems and metering skids?
Yes. As a turnkey EPC contractor we deliver the complete tankage package: ring-wall foundation, dyke wall (with leak-detection sump), fire-water main and hydrants, foam system (NFPA 11 compliant), metering skids, loading/unloading gantries, water treatment, slop oil handling, drainage and full E&I.
How does HAIL ensure quality on storage tank projects?
Documented Inspection & Test Plan (ITP) signed off at FEED. ASME Section IX qualified WPS/PQR for every weld procedure. PMI on every plate batch. 100% RT on Category A & B shell seams. MT/PT on attachment welds. Vacuum-box on bottom. Hydrotest with calibrated chart recorders. Third-party inspection accepted (Lloyd's, BV, T×V, RINA Consulting via consortium). Full data dossier handed over at MC.
Do you build storage tanks for water, fire-water and DM water service?
Yes. NFPA 22 / TAC compliant fire-water tanks, raw water reservoirs, demineralised (DM) water tanks for boilers and process, cooling tower basins, and effluent tanks. Built in carbon steel (with epoxy lining), stainless steel 304/316, or FRP/SMC depending on water chemistry.
Why hire HAIL over a plate-rolling shop or local fabricator?
A storage tank is not just rolled plate. It is a 25-year safety-critical asset that must pass code, statutory and insurance audits. HAIL provides the full discipline stack — engineering, civil, fabrication, NDT, hydrotest, painting, calibration and documentation — under one PO with an ASME / RINA-backed quality system. Local fabricators may quote 30% lower but cannot deliver bankable, code-stamped tanks for refineries.