Case Study: How Macy Industries Engineered a Long-Lasting Surge Solution for an Olympic Pool

March 31, 2025

Macy Industries fabricated stainless steel tanks for this indoor pool. Where does all that water go when an Olympic-sized pool fills with swimmers? For one indoor facility in New York, the answer was a set of aging concrete surge tanks—critical for managing water displacement as swimmers entered and exited the pool. But after years of use, erosion had taken its toll, and the pool’s management team needed a long-term solution. Instead of replacing the tanks with new concrete, they explored a more reliable alternative: custom stainless steel tanks.

The challenge? The new tanks had to fit within a confined mechanical space while integrating with the pool’s existing infrastructure. That meant precise engineering, careful planning, and a fabrication approach that could adapt to tight access points.

Why Stainless Steel?

After years of use, the facility’s concrete system had reached the end of its lifespan. The team needed a more durable, long-term solution—one that wouldn’t require ongoing repairs or structural reinforcements.

Unlike concrete, stainless steel offers exceptional durability without needing protective coatings or frequent maintenance. It’s also more adaptable; if future modifications to the filtration system are necessary, our client would be able to adjust the stainless steel tanks more easily than poured concrete.

Cost was another factor. While concrete requires reinforcement, waterproofing, and precise curing conditions, custom-fabricated stainless steel tanks are built to exact specifications with fewer variables, making them a more practical choice for the facility’s needs.

Precision Engineering in a Tight Space

Custom stainless steel tanksBefore fabrication began, Macy conducted an on-site evaluation to confirm the exact dimensions and identify potential installation challenges. One of the biggest constraints was that the tanks had to pass through a limited-access doorway before installation. To overcome this, Macy designed each tank in two halves—a top and bottom section—allowing for easier transport and on-site assembly.

The final design consisted of three custom stainless steel surge tanks, each constructed from 3/16” stainless steel sheet metal with reinforced angle and channel supports:

  • Tank 1: 70″ W × 80″ L × 96″ D (1,832 gallons)
  • Tank 2: 181-5/8″ W × 80″ L × 96″ D (5,187 gallons)
  • Tank 3: 173-5/8″ W × 80″ L × 96″ D (4,944 gallons)

With a combined 11,963-gallon surge capacity, these tanks ensure the pool maintains a stable water level as swimmers enter and exit. Our team designed each tank with welded pipe flanges, allowing it to be directly connected to the pool’s existing filtration and pump system.

Fabrication and Testing

Once our client approved the sheet metal fabrication drawings, Macy’s team began cutting, welding, and assembling each tank at our facility. Since some tanks weighed over 5,000 pounds, our team carefully planned every stage of production to ensure efficiency and precision.

Before the tanks left our shop, we conducted dye penetrant testing on all welded joints and seams to ensure leak-free performance. This nondestructive testing method detects even the smallest flaws, allowing us to verify structural integrity and ensure long-term reliability.

On-Site Assembly and Final Installation

Due to the facility’s limited entry points, shipping and installation required careful coordination. We transported the tanks in two pieces to accommodate access constraints and carefully maneuvered them into the space.

Once in position, we sealed the sections together using a custom fabricated gasket and secured them with bolts around the mid-flange. This process ensured a watertight connection while allowing for future disassembly if needed.

Although Macy didn’t handle the final plumbing connections, our team provided on-site oversight to guide assembly, ensure proper alignment, and address any last-minute adjustments, helping the client complete the installation with confidence.

A Long-Lasting, Low-Maintenance Solution

With the new custom stainless steel tanks in place, the facility now benefits from:

  • A durable, long-term surge solution that resists erosion and avoids the maintenance issues of concrete.
  • A precision-engineered design that fits the facility’s space constraints while integrating with the existing filtration system.
  • Reduced maintenance costs, with no need for protective coatings or frequent repairs.

By managing the project from design through fabrication and final assembly, Macy Industries helped the client stay on schedule and within budget—delivering a solution that will perform reliably for many years to come.

Looking for a Custom Metal Fabrication Partner?

When precision, durability, and quality matter, Macy Industries delivers. Whether it’s custom stainless steel tanks, structural metalwork, or complex industrial components, our team has the expertise to bring your vision to life.

Let’s talk about your next project. Contact Macy Industries today.