Insulated foam man-way covers for in-ground water tanks located in the Northern USA.
Case Study No. 1 – Insulated Foam
THE CHALLENGE: Our challenge was to provide our customer with an insulated foam cover to prevent in-ground water tanks in Northern USA locations from freezing in the winter months. Our customer’s plastic tank covers were of several different diameters and molded with several different rib patterns based on the weight the cover was required to support. The insulating foam required a R10 value to ensure the tank contents would not freeze.
OUR SOLUTION: We designed a round cover insert from 1# EPS (expanded polystyrene) foam to fit each diameter cover and we routed the rib patter for each size into the foam for an exact fit of the foam insulator into each plastic cover. We employed hot wire profile cutting to cut the round shape and CNC controlled multi-head router to cut the rib pattern. We did have one more trick up our sleeve to ensure the proper R value and this was to foil line the panels on one side to meet the required R10 value.
THE RESULT: A series of professional looking parts which are completely functional from a thermal perspective. We have been producing these parts for many years.