Aluminum Covers

Our continuing design effort has resulted in over a dozen US Patents. These patents not only include the primary structural design but also many of the unique features found only on our cover system. Among these features are the Gear Hinged Access Hatch Panel and the Double Gutter Seal. The Gear Hinged Access Panel allows any individual panel on a cover system to become a fully opening and latchable access hatch. This effectively allows for a cover system that provides total access to the tank below. The Double Seal Gutter proves a continuous double seal for irregular or damaged concrete often found in basin retrofit installations. Both of these features are found only on Hallsten Aluminum Covers.

Once installed, the patented double interlocking deck component assembled into panels and combined with the interlocking beams form a substantially air tight structure. Accurate factory and field testing assures that each cover performs as designed.

Our unique fabrication techniques and the close design tolerances assure that gases and odors are safely contained. Polymer seals are used at every panel edge and at the cover perimeter. These replaceable seals allow the thermal expansion and contraction of the cover without compromising the integrity of the joints. Our unique hatch and penetration details provide minimal leakage through these normally troublesome components.

The non specular surface eliminates the unwanted metallic appearance common with bent metal of covers with smooth extruded deck surfaces. The clean design of our truss supported cover eliminates the multitude of unattractive cross and knee braces common in the designs of our competitors. It only takes one look to see that the Hallsten Aluminum Cover is clearly the most visually appealing cover available.

Every panel on every cover can be individual designed and constructed to provide for high load pedestrian paths and working areas. Only Hallsten Corporation can provide a cover with sufficient strength to withstand concentrated loads in excess of 1000 pounds without permanent deformation. Surface dishing from concentrated load over-stressing, so common with bent metal or inferior component based covers, is eliminated with the Hallsten Aluminum Cover. The panel and beam configuration allows us to design cover structures with extremely high distributed load capacity. This configuration also allows for unlimited geometric options. Covers can be configured in any shape or size; round, rectangular or irregular.

Every connection between adjoining panels includes a corrosion resistant polymer seal. The patented fastener between the beam and the panel is completely chemically resistant and will not weaken or corrode. A mechanical and replaceable Santoprene seal isolates the cover perimeter from the concrete or steel tank wall. No foam tape or caulk is ever used and this critical interface.

When compared to a dome, by reducing the volume of the enclosed gases, the size of blowers, fans, ducts and scrubbers can be reduced with a proportional savings in power consumption. This creates an overall savings, both in initial construction costs and operation. If required, the Hallsten Aluminum Cover can be provided with insulation to minimize heat loss in thermally sensitive processes.

Our panels and beams can be easily removed because there are no corroded sheet metal screws, frozen nuts or wedged seals to hinder access. Each panel can be lifted by hand with only the force of its weight unlike some of our competitors’ designs that require special lifting equipment to pry each panel loose. Each Hallsten Aluminum Cover is as easy to remove as it was to install assuring total access to process equipment. An optional temporary handrail system is available to protect maintenance workers. Each cover includes an integral non-skid surface. Every panel and beam, regardless of position or load capacity, incorporates this surface. Slip resistance is critical to the safely of all personnel.

This simple installation results in a tremendous savings, not only during initial installation, but also in long term maintenance. A cover that is initially easy to install is also easy to remove and reinstall by plant maintenance personnel should the need ever arise.

The primary structural components, the beams, are sized and designed using computer analysis to optimize the structural efficiency of each cover. The stacked beam assembly technique provides us the ability to individually optimize each beam on every unique cover structure. Along with the patented Gear Hinge Access Hatch Panel, deck penetrations and other cover accessories are designed and constructed as an integral part of the cover structure. Deck penetration kits can be field installed to assure that there are no mistakes in the coordination of the trades. Course of construction changes can be easily accommodated with this combination of factory construction and field installable accessories and penetrations. The Hallsten Aluminum Cover has been designed and is manufactured with real world construction in mind.