A method for the construction of an improved tank base. A tank base is constructed for protection against accidental spills and/or leaks associated with a tank battery. The improved tank base comprises at least one part of a suitable substrate, which allows for the adhesion of an elastomer such as polyurea. Polyurea is preferably applied using a spray device which yields an average coverage of about 50-80 mils, and most preferably 60 mils. If more than one substrate is used, one or more substrates can be bound together with a fastening system. Once pressure is applied in the form of weight, the fastening system can be removed, resulting in an improved tank base having at least one seam and impervious to the fluid of the tank battery.
1. A tank base sized to provide a load-bearing support for an above-ground storage tank and configured to allow moisture to pass, the above-ground storage tank having a bottom and defining a diameter, the tank base comprising:
a first encapsulated substrate, comprising:
a first part comprising polystyrene, the first part having a first thickness sized to provide the load-bearing support for the above-ground storage tank, the first thickness being at least about 3 inches; and
a first elastomer encapsulating the first part, the first elastomer comprising polyurea, the first elastomer having a thickness of at least about 50 mils;
wherein the first encapsulated substrate comprises a first planar portion;
a second encapsulated substrate positioned adjacent to the first encapsulated substrate, the second encapsulated substrate comprising:
a second part comprising polystyrene, the second part having a second thickness sized to provide the load-bearing support for the above-ground storage tank, the second thickness being at least about 3 inches; and
a second elastomer encapsulating the second part, the second elastomer comprising polyurea, the second elastomer having a thickness of at least about 50 mils;
wherein the second encapsulated substrate comprises a second planar portion;
wherein the first and second planar portions are coplanar and perpendicular to each of the respective first and second thicknesses of the first and second parts; and
wherein at least one of the first and second encapsulated substrates defines a dimension sized to accommodate the diameter of the above-ground storage tank and to provide the load-bearing support for the above-ground storage tank, the dimension extending in a direction that is perpendicular to each of the respective first and second thicknesses of the first and second parts, the dimension ranging from about 10 to 18 feet;
and
a first seam formed between the first and second encapsulated substrates to allow for moisture to pass between the first and second encapsulated substrates so that moisture is allowed to seep away from the bottom of the tank, via the first seam, when the tank base provides the load-bearing support for the above-ground storage tank.
2. The tank base of claim 1 , wherein the tank base has an outer periphery that is generally circular or oblong in shape;
wherein each of the first and second encapsulated substrates comprises a curved edge portion; and
wherein each of the respective curved edge portions of the first and second encapsulated substrates forms part of the outer periphery that is generally circular or oblong in shape.
3. The tank base of claim 1 , wherein the first and second encapsulated substrates are shaped so that the first seam is interlocking.
4. The tank base of claim 1 , wherein the tank base has an outer periphery; and
wherein the tank base further comprises a strap extending around the outer periphery to hold the first and second encapsulated substrates together.
5. The tank base of claim 1 , wherein the first and second encapsulated substrates comprise first and second edges, respectively; and
wherein the second edge interfits with the first edge to at least partially form the first seam.
6. The tank base of claim 5 , wherein the first edge is vertically offset from the second edge.
7. A kit which, when assembled, forms a tank base sized to provide a load-bearing support for an above-ground storage tank and configured to allow moisture to pass, the above-ground storage tank defining a diameter, the kit comprising:
a first encapsulated substrate, comprising:
a first part comprising polystyrene, the first part having a first thickness sized to provide the load-bearing support for the above-ground storage tank, the first thickness being at least about 3 inches; and
a first elastomer encapsulating the first part, the first elastomer comprising polyurea, the first elastomer having a thickness of at least about 50 mils;
wherein the first encapsulated substrate comprises a first planar portion and a first edge;
and
a second encapsulated substrate shaped to be positioned adjacent to the first encapsulated substrate when the tank base is formed, the second encapsulated substrate comprising:
a second part comprising polystyrene, the second part having a second thickness sized to provide the load-bearing support for the above-ground storage tank, the second thickness being at least about 3 inches; and
a second elastomer encapsulating the second part, the second elastomer comprising polyurea, the second elastomer having a thickness of at least about 50 mils;
wherein the second encapsulated substrate comprises a second planar portion and a second edge, the second edge being adapted to interfit with the first edge to at least partially form a first seam;
wherein at least one of the first and second encapsulated substrates defines a dimension sized to accommodate the diameter of the above-ground storage tank and to provide the load-bearing support for the above-ground storage tank, the dimension extending in a direction that is perpendicular to the first or second thickness of the corresponding first or second part, the dimension ranging from about 10 to 18 feet;
and
wherein, when the tank base is formed and the encapsulated first and second substrates are positioned adjacent to one another:
the respective first and second planar portions of the encapsulated first and second substrates are coplanar and perpendicular to each of the respective first and second thicknesses of the first and second parts;
the first seam is formed between the encapsulated first and second substrates to allow for moisture to pass between the first and second encapsulated substrates; and
the second edge interfits with the first edge to at least partially form the first seam.
8. The kit of claim 7 , wherein, when the tank base is formed and the encapsulated first and second substrates are positioned adjacent to one another, the tank base has an outer periphery that is generally circular or oblong in shape;
wherein each of the first and second encapsulated substrates comprises a curved edge portion; and
wherein each of the respective curved edge portions of the first and second encapsulated substrates forms part of the outer periphery that is generally, circular or oblong in shape.
9. The kit of claim 7 , wherein the first and second encapsulated substrates are shaped so that, when the tank base is formed and the encapsulated first and second substrates are positioned adjacent to one another, the first seam is interlocking.
10. The kit of claim 7 , wherein the first and second encapsulated substrates are shaped so that, when the tank base is formed and the encapsulated first and second substrates are positioned adjacent to one another, the first edge is vertically offset from the second edge.
11. The kit of claim 7 , wherein, when the tank base is formed and the encapsulated first and second substrates are positioned adjacent to one another, the tank base has an outer periphery; and
wherein the kit further comprises a strap adapted to extend around the outer periphery of the tank base to hold the first and second encapsulated substrates together.
12. A kit which, when assembled, forms a tank base sized to provide a load-bearing support for an above-ground storage tank and configured to allow moisture to pass, the above-ground storage tank defining a diameter, the kit comprising:
a first encapsulated substrate, comprising:
a first part comprising polystyrene, the first part having a first thickness sized to provide the load-bearing support for the above-ground storage tank, the first thickness being at least about 3 inches; and
a first elastomer encapsulating the first part, the first elastomer comprising polyurea, the first elastomer having a thickness of at least about 50 mils;
wherein the first encapsulated substrate comprises a first planar portion; and
a second encapsulated substrate shaped to be positioned adjacent to the first encapsulated substrate when the tank base is formed, the second encapsulated substrate comprising:
a second part comprising polystyrene, the second part having a second thickness sized to provide the load-bearing support for the above-ground storage tank, the second thickness being at least about 3 inches; and
a second elastomer encapsulating the second part, the second elastomer comprising polyurea, the second elastomer having a thickness of at least about 50 mils;
wherein the second encapsulated substrate comprises a second planar portion;
wherein at least one of the first and second encapsulated substrates defines a dimension sized to accommodate the diameter of the above-ground storage tank and to provide the load-bearing support for the above-ground storage tank, the dimension extending in a direction that is perpendicular to the first or second thickness of the corresponding first or second part, the dimension ranging from about 10 to 18 feet;
wherein, when the tank base is formed and the encapsulated first and second substrates are positioned adjacent to one another:
the tank base has an outer periphery;
the respective first and second planar portions of the encapsulated first and second substrates are coplanar and perpendicular to each of the respective first and second thicknesses of the first and second parts; and
the first seam is formed between the encapsulated first and second substrates to allow for moisture to pass between the first and second encapsulated substrates;
and
wherein the kit further comprises a strap adapted to extend around the outer periphery of the tank base to hold the first and second encapsulated substrates together.
13. The kit of claim 12 , wherein, when the tank base is formed and the encapsulated first and second substrates are positioned adjacent to one another, the outer periphery of the tank base is generally circular or oblong in shape;
wherein each of the first and second encapsulated substrates comprises a curved edge portion; and
wherein each of the respective curved edge portions of the first and second encapsulated substrates forms part of the outer periphery that is generally circular or oblong in shape.
14. The kit of claim 12 , wherein the first and second encapsulated substrates are shaped so that, when the tank base is formed and the encapsulated first and second substrates are positioned adjacent to one another, the first seam is interlocking.
15. The kit of claim 12 , wherein the first and second encapsulated substrates comprise first and second edges, respectively; and
wherein the second edge is adapted to interfit with the first edge to at least partially form the first seam.
16. The kit of claim 15 , wherein the first and second encapsulated substrates are shaped so that, when the tank base is formed and the encapsulated first and second substrates are positioned adjacent to one another, the first edge is vertically offset from the second edge.