Large-Diameter Tank Fabrication & Erection for North Slope Oil Operations

Project Overview

The project involved five large-diameter shop-fabricated storage tanks, each measuring 23.6 feet in diameter and 50 feet tall. These tanks were part of a major drilling and fuel infrastructure build, one of the largest construction efforts in Alaska’s history.

Due to transportation limitations, the tanks could not be fully assembled at T BAILEY LLC’s Anacortes, WA facility. Instead, a hybrid approach was used. The base and top sections were fully fabricated and painted in-house, while the four middle shell courses were rolled, prepped, and shipped loose. Final erection took place at the nearby Port of Anacortes, leveraging T BAILEY LLC’s proximity to a deep-water port.

This phased plan allowed full control over fabrication and erection while staying within transportation constraints. Following assembly, each tank underwent magnetic particle testing and air testing to verify structural integrity. Once testing was complete, the tanks were finish-painted and insulated on-site at the port, then loaded onto a barge for delivery to Alaska’s North Slope.

Challenges Faced

The project’s most significant challenge was the aggressive six-month timeline, driven by the hard deadline of the final seasonal barge sailing to Alaska on June 20th. Missing this date would have meant waiting another full year for the next available shipment window.

Complicating the schedule further, the specified ASTM A516 Grade 70 steel, selected for its cold-weather durability, had to be formed, tested, and delivered before fabrication could begin. These material lead times delayed shop work and compressed the production schedule even more.

To stay on track, T BAILEY LLC planned for the completion of approximately one full tank per month. This required meticulous coordination between internal teams and multiple subcontractors handling insulation, scaffolding, and transportation logistics.

Instead of transporting fully assembled tanks, T BAILEY LLC shipped the lower tank courses with complex base skids attached, and the roof sections with one shell course pre-installed. This decision allowed the most intricate fabrication work to be completed in a controlled environment, improving quality and eliminating the need to build sensitive components in the field.

The oversized loads, including 24-foot-wide sections, were transported at night through downtown Anacortes to reduce traffic disruptions and ensure safety. These moves required careful staging and permitting in collaboration with the City of Anacortes, Port staff, and local tenants.

Meanwhile, field erection at the port involved working around other contractors and ongoing port operations. Shared space created challenges for crane access, staging, and safety. Daily coordination meetings were essential to maintain progress, minimize conflicts, and keep all parties aligned.

The Key to Our Successful Outcome

Despite the tight timeline and complex logistics, T BAILEY LLC successfully delivered all five tanks on time, with just days to spare before the barge deadline. This achievement was the result of several key strengths:

• In-house, self-performed services: From rolling, welding, blasting, and coating to field erection and testing, the majority of the work was completed by T BAILEY LLC’s own crews. This reduced delays, simplified communication, and ensured consistency from start to finish.
• Strategic port access: Our proximity to a deep-water port allowed us to fabricate oversized tank components in-shop and then transport them just minutes away for final erection and barge loading, an advantage few regional contractors can offer.
• Proven logistical coordination: Close collaboration with subcontractors, the city, and port authorities ensured seamless execution across fabrication, transportation, and field operations. We anticipated challenges and built contingencies into the plan, including extended shifts and weekend work to stay on schedule.
• Experience in harsh environments: From selecting the right steel grade to managing coatings and insulation for Arctic climates, T BAILEY LLC brought the experience needed to meet the project’s environmental demands.

This was not T BAILEY LLC’s first project with Santos, and our performance on this critical job further solidified a strong, trust-based partnership.

Final Thoughts

This project showcases T BAILEY LLC’s full-service capabilities, fabrication, testing, coating, and field erection, executed under a tight deadline for one of the most remote and demanding environments in North America.

Do you have a project that demands speed, scale, and expert execution? Contact T BAILEY LLC today to learn how we can support your infrastructure goals from fabrication through final delivery.