Vertical Systems for Tank Production - Carell...

Vertical Systems for Tank Production™

251-937-0947 · www.carellcorp.com

Crane Systems, Field Production

Stainless Systems, Shop & Field

Mild Steel & Stainless Systems

Jack-Up Systems, Field Production

Mild Steel Systems, Shop & Field

Vertical Tank TechnologyIMCAR develops and produces Vertical Tank Technology systems to manufacture tanks and silos suitable for a wide range of industrial applications: petroleum, pharmaceutical, wine, water, beer, dairy, fruit juices, chemical products, liquid gases, etc.

Innovative production cells, starting from coils and plate, now enable the production of tanks in the most efficient and expedient methods, following the subsequent operations of bending, cutting, welding, surface prep and cleaning until completion of the final product.

IMCAR’s dedication to the best production methods and quality offers turn-key solutions and customized study for each industrial application, production requirements, start-up and training needs.

Tandem Forming Operations Tandem Welding Operations

Vertical Decoil & Roll

VerticalCut

Weld& Clean Ve

rtica

l Pro

duct

ion

Circumferential

Align, Weld, Planish & Clean

WELDING STATIONCircular Alignment > Circular Welding > Weld Compression > Circular Weld Cleaning

FORMING STATIONDecoiler > Plate Bending > Surface Polishing > Cutting > Welding > Weld Cleaning

y Reduce labor costs & number of skilled workers

y Reduce required shop space

y Reduce material costs by using coil material

y Reduce raw material storage space

y Reduce material handling time

y Eliminate cross contamination between ferrous and non-ferrous metals. Contact components are made of non-contaminating non-ferrous materials

y Increase consistency of finished product

y Increase rolling & welding quality

y Increase surface finish quality

y Increase consistency

y Increase production throughput

y Increase flexibility, tank diameters from 6’ to 65’+

y Increase versatility, produce in-house or on-site

Benefits of Advanced Vertical Tank Production Technology

HEAD FORMING y Press & Manipulator y Circular Shearing & Flanging y Head Polishing

TOP & BOTTOM PRODUCTION y Circular shearing/flanging machine y Press and Manipulator for domed heads

TAPERED TANK LEG FORMING PRESSES

COMPLETE CLEANING & POLISHING SOLUTIONS y Internal / External Tank Surfaces y Vertical Weld Seam y Horizontal Weld Seam

LIMPET COIL PRODUCTION y Forming - Bending - Welding flat or half pipe circulation coils yWeld seam cleaning y Cooling panel production

251-937-0947 · www.carellcorp.com · [email protected]

Components and equipment for surface polishing and satinizing of inside and outside surfaces are optional on all vertical systems.

Station 1 for Shell Forming

Decoiling Shell Rolling

Vertical Cutting Vertical Welding

Vertical Systems for Tank Production™ are composed of individual or groups of dedicated “Stations” that can be tailored to fit various manufacturing requirements.

Our Systems are designed to Increase your Output, Consistency and Product Quality and will Reduce your labor, material handling and shop/yard space requirements.

Vertical Tank Production Cell Options

We Integrate the latest technology in bending, cutting, welding, surface prep and finishing into a powerful production cell.

Shell Forming Data & ComponentsFeed Stock Coils 6 ton to 30 ton, Flat Plate

Coil/Plate Height Coil 2’ to 8’ / Plate 2’ to 12’

MaterialsMild & Carbon Steels, Stainless, Aluminum, Other

Material Thickness 20 Gauge to 1”

Shell Diameters Up to 30’ Ø Shop / Up to 150’ Ø Field

Stainless OptionsProtective Paper Removal, Protective Film Application

Surface FinishingSatinizing, Polishing Inside/Outside Surfaces

Vertical Cutting Plasma or Abrasive Disc

Vertical Welding MIG / TIG / Plasma / CMT / Other

Vertical Weld Cleaning Inside and/or Outside

Required Manpower 1 Operator + 1 Helper


Stainless

Mild Steel

Station 2 for Circular Welding

y Select Welding/Cutting Methods y Select Welding/Cutting OEMs y Turn Key Complete Systems

y Order Separate Components y Order Portable Systems, Shop & Field y Complete Finishing Solutions

Shell Alignment Circular Welding Weld Planishing Weld Cleaning

Flexibility in Design & Solutions

Circular Welding Data & Components

Motorized Table Versions with and without support templates

Shell Diameters Up to 30’ Ø Shop / Up to 150’ Ø Field

Materials Mild & Carbon Steels, Stainless, Aluminum, Other

Material Thickness 20 Gauge to 1”

Shell Alignment Compression Heads or standard

Circular Welding TIG / MIG / Plasma / CMT / Other

Weld Planishing Compression Heads, Hydraulic

Circular Weld Cleaning Inside / Outside / Belt or Disc

Shell Heights 2’ to 8’ (individual shells)

Tank Heights No limits

Required Manpower 1 Operator + 1 Occasional Helper

Welding and cutting generators and torches excluded, select your preferred supplier and equipment.


In-Field Systems DataMachine coatings and components designed for outdoor environments

All weatherproof connectors, cables & stainless switchgear cabinets

Portable design for ease of transport and set-up, modular 40’ racks optional

Designed to work with coil and/or flat plate

Automatic Circular Welding: TIG / MIG / Plasma / CMT / Other

Shell Alignment, Planishing, and Weld Cleaning

Designed to work with crane or jack towers for tank hoisting

Plate Capacity: To 1” or thicker on request

Tank Diameter Range: 10’ to 150’ +

Vertical Tank Technology for Field Production

Use our Jack Tower systems or rental cranes

Ease of Transport & Setup with modular

rack options

Up to 1” Capacity

150’+ Diameter

Engineered for Harsh Environments

IMCAR’s Vertical Tank Production Technology is designed for easy transport and field setup. Systems can be designed to process both coil stock and sheet stock to provide maximum field production capabilities. Significantly reduce the number of field crew and increase production efficiency with IMCAR’s Vertical Tank Production field system.

Process either Flat Sheet or Coil Stock


Cooling & Heating Systems for Vertical TanksDramatically shorten production times, and scale down labor costs with our semi-automatic and fully automatic limpet pipe and coil production solutions.

Semi-Automatic Half Pipe Production

Fully Automatic Half-Pipe Production

Half-Pipe Systems DataProduction half pipe for cooling system From Coil

Thickness From 20 Ga to 9 Ga

Polishing outside surface

Special table for spot welding of half pipe direct on shell

Motorized Table From Ø 3’ to 5’ Standard More than 5’ available on request

Welding manipulator with dual tracking for automatic welding of half pipe

You can significantly reduce traditional production cycle times and achieve superior results with one operator in a fraction of the time.

• Form half pipe coils from coil or strip using traditional 3 roll benders.

• Produce, tack and weld half pipe coils in semi and fully auto modes from coil stock.


“Up-Ender” Coil Tilting Machine

CB5000 Circular Shearing & Flanging Machine

“Up-Ender” Coil Tilting Machine

Vertical Straightening Machine

Tank Leg Forming Machine

Vertical Tank Material Handling & Forming Options

Technical Data and ConfigurationsCircular Shearing & Flanging Machine

Max. & Min. Cutting & Flanging Thickness Capacity

From 0.40” to 0.310”

Max. Cutting & Flanging Diameter 16’

Max. Radius at Flange 2”

Max. Total Height of Conical Tank End 15.75”Coil Up-Ender Tonnage Capacity Range 6 to 30 tonsVertical Straightening Machine

Height & Capacity Stand Alone or Integrated

Any size

Leg Forming Machine Bending Capacity, Stainless Steel 10 Ga x 60”

Bending Capacity, Mild Steel 9 Ga x 60”


Integrating the latest advances in bending, cutting, welding, surface prep and finishing technology.

Vertical Systems for Tank Production™

Around the Globe.

Providing Solutions and Technology to North American Fabrications for 20 Years

IMCAR develops and produces vertical tank production systems that are designed to bend, cut, weld, clean, prep, and finish tanks of all types rapidly and consistently. Now you can significantly decrease traditional tank production costs, maximize your production throughput and profit, and increase your competitive advantage.

IMCAR’s Vertical Tank Production Systems are streamlining tank production around the world, with over 90 installations in over 30 countries, including:

Integrating the latest advances in bending, cutting, welding, surface prep and finishing technology.

Contact Carell Corporation for IMCAR Vertical Tank Technology solutions and consultation.

251-937-0947 · www.carellcorp.com34225 US Hwy. 31 · Stapleton, Alabama 36578 · [email protected]

Automated Production Cells, in a variety of sizes and options

3 & 4 RollVertical

Plate Rolls

3 & 4 Roll Plate Rolls

• United States

• Mexico

• Guatemala

• Venezuela

• Colombia

• Chile

• Peru

• Argentina

• Brazil

• Puerto Rico

• Algeria

• Morocco

• Kuwait

• Libya

• Italy

• France

• UK

• Portugal

• Spain

• Germany

• Holland

• Belgium

• Switzerland

• Poland

• Hungary

• Australia

• Russia

• Ukraine

• Siberia

• India

Universal & Dedicated Profile Bending Rolls with CNC options

Vertical Systems for Tank Production - Carell...

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