Leveling the top of a metal frame

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Well, first off, good catch for not filling that. Based upon your pic and description, there is a bow in the middle of the stand, such that all corners are like the pic, correct?

My first move would be to measure the deflection across the entire top using a 2/3 foot level. You may have more deflection near the center than at the corners. Secondly, I'd try to get the stand fixed, whether that means hammering down the center, re welding, grinding down the center, re bracing, whatever.

If fixing the stand does not work (and being welded metal it just might not), I'd probably not use self leveling concrete. I've worked with that before, and maybe it's because it was my first time, but it didn't actually level flat. It leveled 'close' to flat, but not close enough. Then I had to use a concrete grinder to "fix" it. Yikes with all the dust and extra trips. It was ok because it was just my basement and I was going to cover it with tile, but wow, more work than I wanted. Not to mention that unreinforced concrete is prone to cracking, so not sure how long that fix will work.

From the description, you can't actually shim between the floor and tank to fix this issue. It's not that the stand is flat on the top, but tilted; it's simply not flat.

I like the idea of getting a thicker plywood, (1/2" might work, but I'd use at least 1" with something like this), then shimming it. If it's only the edges, and if you shim along the entire edge on all sides, you should be fine. Use good shims (metal?) and as you already said, not just 1 at each corner, but a plentiful number to prop the entire corners on every side.

Do that and re measure the deflection across the plywood and prove to yourself that it's level everywhere across the top. Then fill the tank and enjoy.
 
^ This, I know it would be a pain in the *** to get the tank off but I would get it off and find exactly where it is has the (lump) or imperfection and then looking at how severe it is go about hammering, grinding, or re-welding. Thats 400 gallons of water and doing some quick math, 400*8.3=3320 pounds of water. I would really hate that much water all over my house if a seem bursts.

Take the tank off and grab a 6 foot level and start side to side and then front to back to get an idea of where the spot it, find it and then hammer it down! Good luck and only way I would do it instead of a quick fix when dealing with that much water.
 
can you turn the stand upside down? if the base is level then use the base to support the tank and shim / level the top with the floor? if that makes sense?

Otherwise the plywood idea sounds good but I would use compressed cement sheeting over shims, you can cut them to prefect size and support the whole area. getting the right thickness will be a pain but worth it imo.
 
Firstly thanks for all the replies.

I've been away a couple of days and I think the gap has got smaller as the tank settles into the foam (my wife has now made some marks on the foam to see what happens and confirm the compression), it was only placed on the stand on Sunday. I'm going to be away for most of the next 2.5 weeks so will leave it until then and see how much it settles.

Please note my plan is to still remove the tank (no small job and will take 6 of us!) and sort it out but this will give me an idea of whether the empty tank is going to level itself. Just to reiterate, my plan is to get the top 100% level before I fill it, as has been pointed out its a huge amount of water and weight!

I don't think I am going to be able to do much to change the stand, it currently seems the best plan is a thicker piece of ply and a thicker piece of foam and some shims between the ply and stand, the problem is worse in the front corners, the back corners are not so bad - 1 back corner has no gap and the other is a lot less than the front, the front right is the worst. 1 thought I have had is to get some 2" wide strips of 3mm steel and get them tacked on the end corners and then finish off with shims.

For the concrete idea I considered finishing the top with self leveling screed - I had this done on my flooring before they laid it (as seen in the picture below). Apparently it sets as hard as concrete but I don't think its designed to be used as a slab and only something for finishing. My other thought around the concrete was to add some steel mesh to it for strength. The biggest catches I see with the concrete are it could be brittle and also will need a month without the tank on it to set - so the shimming idea is much more feasible and can be done in a couple of hours.

I have thought about turning the stand upside down, however its been designed to stand a certain way - please see the picture below.

IMAG1038.jpg

IMAG1038.jpg
 
Sounds like a good attack plan!

I would not trust self leveling compound for such weight, I believe due to the amount normally used it would crack under such pressure, my biggest worry is if the house is to move etc it would crack far greater then a 100mm slab with rio in it.

As for the turning the stand upside down, I dont see the issue, the verticals will take the pressure into the base. I could be wrong.. you do seam to have some cross beams welded in though which may get in the way if your attempting to install a sump etc but in my brain which is quite horrible at times :P the pressure is going to be distributed the exact same over these parts.
 
My plan is to put a sump under the tank (which I already have) so turning the stand upside down is not going to work as the supports get in teh way of the sump.
 
I agree with squirtle...id just flip the stand. Those weird supports are in ur way regardless. Id never sell a stand like that lol...have u tried getting it fixed from the maker? Looks like the legs in the center were cut too long. Not a hard job for the guy to cut them out and reweld.

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Have a new top out of the same size SHS made and then weld in place on top of the existing stand

Didnt think of that...best idea yet! Very easy fix, that should be done at the sellers cost since he made it so unlevel.

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Don't want to say much but those are some cold welds buddy.
Lots of undercuts also.
Would grind and redo.

Just my opinion though.

Jeff
 
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