Insurance of construction and installation risks when installing PP tanks” 

Insurance of construction and installation risks when installing PP tanks: a direct answer to the main question

Insurance of construction and installation risks (CEM) during the installation of polypropylene containers is not just a formality for obtaining permission to work, but a critical financial instrument that covers damage from accidental damage to expensive equipment during its assembly, testing and commissioning. In our practice, we have repeatedly encountered situations where the lack of a construction and installation insurance policy led to the complete bankruptcy of the contractor after a single incident with a seam depressurizing or a tank section falling. The policy must be valid from the moment the first part is delivered to the site until the signing of the acceptance certificate to the customer, including the trial run period. If you are planning to install a tank with a volume of more than 50 m³ or a height of more than 4 meters, the availability of specialized insurance is a prerequisite to protect the investment of both the customer and the contractor.

Many people mistakenly believe that standard property or liability insurance will cover any problems on a jobsite. This is a dangerous misconception. Regular property insurance begins to operate only after the property is put into operation and entered into the balance sheet of the enterprise. The installation period, when the tank is in its most vulnerable state - sheets are assembled, seams are welded, hydrotesting is carried out with water - remains outside the coverage area of ​​normal policies. This is where it comes into effectстрахование строительно-монтажных рисков при установке PP резервуаров. This type of insurance is designed specifically to cover risks arising during the dynamics of construction work, where the likelihood of an accident is greatest.

Specific risks when working with polypropylene: why standard approaches do not work

Polypropylene (PP) as a structural material has unique physical and chemical properties that fundamentally distinguish the process of its installation from working with metal or concrete. Understanding these differences is necessary to correctly formulate the sum insured and exclude from the policy. The main feature of PP is its high sensitivity to temperature conditions during welding and mechanical loads when lifting large components. Unlike steel, polypropylene does not forgive mistakes in extrusion welding technology: overheating leads to destruction of the material, underheating leads to a lack of seam integrity. Insured events related to defects in welded joints account for up to 60% of all losses during the installation of chemical tanks.

In our practice, an illustrative case was recorded that clearly demonstrates the need for in-depth study of the terms of the insurance contract. One of our clients, a large chemical plant, ordered the installation of a 200 m³ storage tank for aggressive reagents. The contractor, trying to save money, did not take out an extended construction and installation work policy, limiting himself to the minimum package. During hydrotesting, due to a sharp change in night temperatures (from +15°C to -5°C), a brittle rupture of the tank bottom occurred in the area of the technological hatch. Polypropylene loses its impact strength at low temperatures. The damage amounted not only to the cost of the tank itself (about 4.5 million rubles), but also to the costs of eliminating the chemical spill, cleaning the area, and production downtime. The insurance company refused to pay, citing the fact that the policy did not specify the conditions for testing at low temperatures and did not take into account the specifics of the material. This lesson cost us dearly, but it proves:страхование строительно-монтажных рисков при установке PP резервуаровshould be individual, not typical.

Another critical aspect is wind loads when installing large sections. Polypropylene sheets have significant windage. When assembling tanks over 6 meters high in open areas, the risk of the unfinished structure toppling over during a sudden squall increases many times over. Metal frames have their own weight, which stabilizes the structure, while the PP tank is extremely unstable until the piping and backfilling is completed (if provided). The insurance policy must explicitly cover the risks of natural disasters, including hurricane winds, hail and flood, taking into account the geographical location of the property. Ignoring this point may lead to a situation where a strong gust of wind will destroy the already assembled tank dome, and the loss will fall solely on the shoulders of the customer.

Key factors influencing insurance premium

• Tank volume and geometry:The larger the diameter and height, the higher the stability risks and the complexity of installation work. Tanks with a volume of over 100 m³ require the development of a work execution plan (WPP), the availability of which is often a mandatory requirement of the insurer.
• Load lifting height:Using cranes to install rings or prefabricated sections at heights greater than 10 meters significantly increases the risk factor. Insurers carefully study the lifting capacity of equipment and the qualifications of crane operators.
• Conditions for hydrotesting:The water test creates a colossal load on the walls and base. Mistakes in foundation preparation or excessive filling rates can lead to disaster. This stage is always charged separately as the period of maximum danger.
• Installation crew qualifications:The presence of NAKS certificates (or international analogues) for welders to work with polypropylene reduces the policy rate. Insurance companies trust the proven competence of their staff.

What exactly does the construction and installation policy cover: analysis of the damage structure

A properly drafted insurance contract for construction and installation risks when installing PP tanks should cover a wide range of possible losses. However, it is important to understand the difference between direct damages and associated costs. Basic coverage usually includes loss or damage to the insured property itself (tank, components, materials) as a result of an insured event. This includes fire, explosion, falling objects, installation errors, and illegal actions of third parties. But this is not enough for complete protection.

Particular attention should be paid to covering the costs of clearing debris (Debris Removal). When a large polypropylene tank breaks, it produces a huge amount of plastic scrap, which is often contaminated with chemicals. Disposal of such waste requires the involvement of specialized organizations and compliance with strict environmental standards. The cost of removal and disposal can reach 15-20% of the cost of the tank itself. If this clause is not explicitly included in the policy, the customer will have to pay for this work out of his own pocket. In one of our projects in Siberia, the cost of disposing of a damaged tank with residual petroleum products amounted to more than 800 thousand rubles, which was an unpleasant surprise for the project budget.

Covering emergency response costs is also critical. If an accident occurs with a spill of contents, immediate action is required to localize the contamination, pump out the liquid and neutralize the consequences. These works are carried out around the clock and require expensive equipment and reagents. The standard liability limit is often insufficient for such scenarios. We recommend increasing the limit on this item by at least 1.5 times relative to the estimated cost of possible work. In addition, the policy must cover the cost of re-testing. If the first hydroplane was unsuccessful due to an insured event (for example, a seam break), the costs of water, electricity for pumps and personnel work when trying again must also be compensated.

Do not forget about civil liability to third parties (Third Party Liability). Installation of tanks is often carried out in close proximity to existing production facilities, warehouses or transport routes. A falling structural element, a spark from a welding machine, or the collapse of scaffolding can damage neighbors' property or injure bystanders. The limit of liability under this clause must be comparable to the potential maximum damage. For industrial zones, we recommend setting a limit of at least 10-20 million rubles, taking into account the high cost of industrial equipment and possible environmental fines.

Typical exceptions: where the insurance company will refuse to pay

Knowing the exclusions from coverage is just as important as knowing the covered risks themselves. Insurance companies carefully analyze each case and use any clues in the contract to refuse payment. The most common exceptions are material defects and manufacturing defects. If a crack in the tank body occurred due to a violation of sheet extrusion technology at the manufacturer, construction and installation insurance will not cover this. This is the responsibility of the equipment supplier and the quality guarantee of the plant. However, it can be extremely difficult to prove that the reason is a defective material, and not a mistake by the installer, and requires an independent examination, which also needs to be able to be organized correctly.

Another important exception is natural wear and tear and gradual deterioration of the material. Polypropylene is susceptible to aging under the influence of ultraviolet radiation if it does not have appropriate stabilization. If the tank stood for six months in the open sun without protection before installation and lost its strength, subsequent destruction will not be recognized as an insured event. The contract must clearly state the requirement for storage conditions for materials before the start of work. We always record the delivery date and storage conditions with a photo report in order to exclude claims from the insurer for improper storage.

Gross Negligence is a concept that is interpreted broadly. If the commission determines that the accident occurred due to deliberate disregard of safety rules or technological map (for example, welding at a temperature below the permissible temperature without heating), the insurance company has the right to refuse payment. It is important to note that ordinary error by the employee (simple negligence) is usually covered, but systematic failure of instructions by the contractor's management may qualify as gross negligence. Therefore, the presence of welding quality control logs and hidden work reports is not only a GOST requirement, but also a way to protect insurable interests.

War and terrorism exclusions are standard on most policies unless a special extension is purchased. Losses caused by nuclear reactions or radiation are also often excluded. For chemical plants, it is important to check the pollution exclusion clause. Many basic policies exclude losses from gradual pollution, covering only sudden and unexpected releases. If your tank is intended to store highly toxic substances, you must negotiate a special provision to cover environmental risks.

Procedure for registration and interaction with the insurance company

The process of obtaining a policy begins long before the team enters the site. The optimal time to contact the insurer is the stage of developing project documentation. At this stage, technical solutions can be adjusted to reduce risks and, accordingly, the cost of insurance. To calculate the premium, the insurance company will request a package of documents: design documentation for the tank (section KM or KMD), work schedule, installation estimate, information about the contractor (licenses, SRO approvals), characteristics of the construction site (geology, climate).

Estimating the sum insured is a key point. It must include the full cost of the turnkey tank: the cost of materials, delivery, installation work, commissioning operations and VAT. Understating the amount insured in hopes of saving on premiums is a dangerous strategy. In the event of total loss of the object, payment will be made in proportion to the ratio of the insured amount to the actual value (proportion rule). That is, if you insured an object for 50% of the actual value, then you will receive only 50% of the damage. Saving on a premium of 10-15% can result in the loss of millions of rubles if an insured event occurs.

An important step is the inspection of the property by an insurance surveyor. Before work begins, a representative of the insurance company visits the site to assess the risks. He checks the preparation of the base, the presence of fences, the condition of lifting equipment, and the qualifications of personnel. The surveyor's recommendations are binding. If it requires the installation of additional windbreaks or strengthening of the foundation, compliance with these requirements must be recorded in an act. Ignoring the surveyor's instructions gives the insurer a legal basis for refusing to pay in the future.

During the installation process, it is necessary to conduct careful paperwork. All changes in the project, schedule delays, and downtime due to weather must be recorded. When an insured event occurs, actions must be taken at lightning speed: notifying the insurance company within the period specified in the contract (usually 24-48 hours), taking measures to save property, preserving the scene of the incident for inspection. Drawing up an insured event report together with a representative of the insurer is a critical procedure. Any inaccuracies in the description of the causes and circumstances may be used against you in settling a loss.

Comparative analysis of insurance options: savings versus reliability

There are many offers on the market for construction and installation insurance, ranging from cheap “conveyor” type products to complex programs from leading reinsurance companies. The choice depends on the scale of the project and the risk appetite of the customer. Cheap policies often have high deductibles (the portion of damage not covered) and long lists of exclusions. They are suitable for small projects where the cost of the tank is low and the potential damage does not threaten the financial condition of the company. However, for large industrial tanks this approach is unacceptable.

Below is a table comparing two typical approaches to insuring the installation of PP tanks:

For high-risk facilities, such as tanks for acids, alkalis or food products, where the cost of product downtime or contamination amounts to millions per hour, the choice is obvious in favor of an extended policy. Savings on insurance in the amount of several hundred thousand rubles are not comparable with the risk of losing a multimillion-dollar contract or reputation. В нашей компании мы настаиваем на использовании премиальных программ страхования для всех проектов объемом свыше 50 м³, считая это неотъемлемой частью культуры качества и безопасности.

Юридические аспекты и соответствие стандартам ГОСТ и СНиП

Страхование строительно-монтажных рисков при установке PP резервуаров тесно переплетено с требованиями российского законодательства и отраслевых стандартов. Хотя прямое требование страховать СМР для всех объектов отсутствует в Градостроительном кодексе (за исключением опасных производственных объектов, где требуется страхование ответственности), контрактная практика крупных заказчиков (Газпром, Роснефть, Сибур) делает наличие полиса обязательным условием допуска к тендерам. Отсутствие полиса автоматически дисквалифицирует подрядчика.

При оформлении договора важно ссылаться на актуальные нормы. Монтаж полипропиленовых резервуаров регламентируется сводами правил по производству пластмассовых изделий и строительных конструкций. Страховщик может потребовать подтверждения соответствия проекта требованиямГОСТ 27308(Пластмассы. Методы испытаний на стойкость к химическим средам) или техническим регламентам Таможенного союза. Если проект выполнен с отступлениями от норм, страховая компания может отказать в покрытии или существенно завысить тариф, рассматривая объект как повышенно опасный.

Особое внимание следует уделить пункту о суброгации. Это право страховой компании, выплатившей возмещение, требовать компенсации с виновника ущерба. В контексте монтажа резервуаров это означает, что если авария произошла по вине субподрядчика (например, крановой компании), ваша страховая выплатит вам деньги, а затем сама будет судиться с субподрядчиком. Это освобождает вас от долгих судебных тяжб. Однако, если в договоре с субподрядчиком вы заранее отказались от права регресса, страховая компания может отказать в выплате, так как вы лишили ее возможности вернуть свои деньги. Проверка договоров с контрагентами на предмет права регресса — обязательная за дача юриста перед подписанием полиса.

Практические рекомендации по минимизации рисков и снижению стоимости полиса

Стоимость страхования не является фиксированной величиной и подлежит négociation. Существует ряд мер, реализация которых позволяет легально снизить страховую премию без ущерба для качества покрытия. Во-первых, внедрение системы менеджмента качества (СМК) на объекте. Наличие сертифицированной по ISO 9001 системы у подрядчика говорит страховщику о том, что процессы контролируются, а брак сведен к минимуму. Предоставление сертификата ISO может снизить ставку на 10-15%.

Во-вторых, использование современного оборудования для сварки. Автоматические экструдеры с цифровым контролем параметров температуры и скорости подачи прутка значительно надежнее ручных аппаратов. Фотофиксация процесса сварки и ведение электронных журналов параметров повышают доверие андеррайтера. В-третьих, правильный выбор сезона для монтажа. Проведение основных работ в летний период исключает риски, связанные с низкими температурами и обледенением конструкций, что положительно сказывается на тарифе.

Мы рекомендуем проводить предварительный аудит рисков силами независимых экспертов до обращения в страховую компанию. Выявление и устранение слабых мест на этапе подготовки позволяет прийти к страховщику с уже оптимизированным профилем риска. Также стоит рассмотреть вариант франшизы. Увеличение безусловной франшизы (суммы, которую вы платите сами при любом ущербе) — самый эффективный способ снижения стоимости полиса. Если ваша компания готова самостоятельно покрывать мелкие ремонты (царапины, небольшие подрезы швов), то ставка по полису может снизиться в разы, при этом защита от катастрофических рисков сохранится.

Заключение: страхование как инвестиция в надежность

To summarize, it can be stated thatстрахование строительно-монтажных рисков при установке PP резервуаровявляется неотъемлемым элементом профессионального подхода к строительству промышленных емкостей. Это не просто статья расходов, а механизм финансовой защиты, позволяющий сохранить бюджет проекта и деловую репутацию в форс-мажорных обстоятельствах. Специфика полипропилена как материала требует внимательного отношения к деталям полиса: от условий хранения листов до процедуры гидроиспытаний.

Опыт показывает, что попытки сэкономить на страховке или использовать типовые шаблоны договоров неизбежно приводят к проблемам при урегулировании убытков. Только индивидуальный подход, учитывающий геометрию резервуара, климатические условия площадки и квалификацию персонала, обеспечивает реальную защиту. Мы настоятельно рекомендуем начинать проработку вопроса страхования параллельно с проектированием, привлекая опытных брокеров, специализирующихся на промышленных рисках. Помните: цена полиса неизмеримо меньше стоимости восстановления разрушенного резервуара и ликвидации последствий аварии.

Комплексный подход к безопасности промышленных объектов включает не только грамотное страхование, но и выбор надежного поставщика основного оборудования. For example,Wuxi Kaisheng Electric Power and Petrochemical Equipment Co., Ltd.специализируется на разработке и производстве высококачественного теплообменного и нефтехимического оборудования, которое часто работает в связке с резервуарными системами. Продукция компании, включая титановые кожухотрубные теплообменники, ASME высоконапорные аппараты и трубные пучки из специальных сплавов (никель N06625, морская латунь C46400, нержавеющая сталь 316/321), сертифицирована по международным стандартам PED и ASME. Высокая коррозионная стойкость и способность работать при экстремальных давлениях и температурах делают оборудование «Уси Кайшэн» идеальным выбором для нефтеперерабатывающих, химических и энергетических предприятий по всему миру. Использование такого проверенного оборудования в комплексе с правильным страхованием монтажа создает максимально защищенную инфраструктуру для вашего бизнеса.

Если вы планируете монтаж резервуарного парка и хотите подобрать оптимальную программу страхования, которая учтет все нюансы работы с полипропиленом, или нуждаетесь в поставке надежного теплообменного оборудования, свяжитесь с нашими специалистами. Мы поможем проанализировать ваши риски, найти надежного партнера среди страховых компаний и предложим лучшие технические решения.Contact us todayдля получения консультации по вопросам страхования ваших промышленных объектов и поставки оборудования.