Project Information
| Client | Industrial Plant, Australia |
| Requirement | Structural upgrades and access system design for five large storage tanks |
| Inputs | Incomplete DWG files (incompatible with SolidWorks) |
| Software | SolidWorks |
| Deliverables | General Assembly Drawings (GA), Shop Drawings (DWG/PDF) |
| Services | 3D Tank Modeling, Structural Design, Shop Drawing Generation, Access System Engineering |
Objective
The project’s primary objective was to design and deliver a reliable access and structural support system for five industrial storage tanks. This included developing I-Beam floor frameworks, Surline panel hatches, and Z Purlins while ensuring safety, leak prevention, and accurate fabrication-ready documentation.
The client wanted a complete set of General Assembly (GA) and shop drawings for fabrication and installation.
Project Summary
Our client, a leading industrial operator in Australia, required comprehensive structural modifications for five storage tanks. The project scope included floor support structures, safe access hatches, and rain/fume control systems.
The challenge was heightened due to incomplete and incompatible DWG inputs. Each tank had unique cutouts, pipe penetrations, and geometry variations. This made it difficult to reuse the same model. Our engineering team rebuilt all five tanks from scratch in SolidWorks with exact dimensions and features before progressing to structural design.
Through a systematic approach, we delivered accurate tank models, structural weldment frameworks, weatherproof Z Purlins, and detailed fabrication drawings.
Challenges
The major challenges faced during the project included:
- File Compatibility Issues: DWG files provided were incomplete and not fully compatible with SolidWorks.
- Missing Geometry: Several critical tank details (cutouts, pipe holes) were absent.
- Tank Variations: Each tank had distinct geometrical features. Hence, a single reusable model cannot be created.
- Drawing Complexity: Large-scale assemblies required strict version control and phased approvals.
Our Strategic Approach
To address these issues, our team adopted the following methodology:
1. Tank Reconstruction in SolidWorks
Since the DWG files provided were incomplete and incompatible, our engineers rebuilt all five tanks manually using site measurements and client references. This ensured that each model accurately represented – pipe penetrations, cutouts, and overall geometry, providing a reliable foundation for further design work.
2. Structural Design
Our designers developed I-Beam frameworks using weldments to support the floor panels and access hatches within each tank. Surline panels with hatches were integrated to allow safe personnel entry while incorporating weatherproofing measures. Additionally, Z Purlins were designed in sheet metal to divert rainwater and limit the escape of fumes, ensuring both structural integrity and safety compliance.
3. Drawing & Documentation
General Assembly (GA) drawings were prepared to illustrate the complete tank assemblies, showing I-beam layouts, hatch placements, and Z-purlin configurations. Shop drawings were also created. They provided detailed fabrication guidance for assembly and included cut lists, welding symbols, and material specifications required for manufacturing.
4. Client Collaboration
Iterative review cycles were conducted to validate the models and drawings, ensuring client approval before moving into fabrication. This collaborative approach reduced revisions, maintained accuracy, and streamlined the overall project delivery.
Project Deliverables
Our structured workflow resulted in:
- Accurate Tank Models: Five fully rebuilt SolidWorks models with precise cutouts and geometry.
- Customized Structural Components: I-Beams, Surline panels, and Z Purlins tailored for each tank.
- Fabrication-Ready Drawings: Comprehensive GA and shop drawings in PDF/DWG formats.
- Improved Access & Safety: Enhanced structural integrity, leak prevention, and safe personnel entry.
Result & Impact
| Key Area | Before (Inputs) | After (Our Solution) |
| CAD Inputs | Incomplete, incompatible DWG files | Fully rebuilt SolidWorks models |
| Structural Support | No safe framework | I-Beam floor structures and Surline access hatches |
| Weather/Fume Protection | Leakage and exposure risks | Z Purlins for rainwater diversion & fume control |
| Documentation | Fragmented, missing details | Complete GA + Shop drawings for fabrication |
Tools & Technologies Used
- SolidWorks 3D CAD: Weldments, Sheet Metal, Assembly Modeling, 2D Drafting
- DWG/PDF Outputs: Deliverables aligned to the client’s fabrication standards
- Collaborative Review Cycles: Ensured quality assurance and approval checkpoints
Conclusion
Even though the source files were incomplete and the tanks had different shapes, our engineering team successfully designed and delivered a full structural and access system for five industrial tanks. Using SolidWorks and a careful documentation process, we created accurate fabrication drawings that reduced the need for rework on-site.
Our customized approach also strengthened the client’s confidence in our ability to handle complex design challenges, even under strict technical limitations.
Looking for reliable CAD modeling and structural design support? Partner with Enginerio today and let our experts deliver precision-driven solutions for your next project.
