Karim's 1500gal dream reef

Sure. The 42" wall is likely 1" but the rest doesn't need to be.

Structure does matter - the rules of thumb apply to classic tank shapes. But remember that the eurobraced reduced the glass thickness necessary, etc...

When I considered a drop off tank, the stresses on the inner corner of the L sides was a real concern. A centrally braced tank had reduced stresses overall. The bottom being wood, concrete or plastic is certainly a realistic option.

The purpose of sharing this design is exactly to bring these issues out. It's not to bring the thread down, but it is to vet out and come up with a better design. :D
 
ok. I have a minute to share more about the design, so here come the details.

First, location location location.

1. The site needs to be SOUTH facing (since I'm in Dallas, TX).
2. There can be no tall trees or buildings within 100ft south, east or west.
3. The space allocated to the DT room is a fraction of the total space. The tank room and work room are substantially larger.

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/0_zpsyuoa0ell.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/0_zpsyuoa0ell.png" border="0" alt=" photo 0_zpsyuoa0ell.png"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/1_zpss0phgbdx.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/1_zpss0phgbdx.png" border="0" alt=" photo 1_zpss0phgbdx.png"/></a>
 
Ok. My current sunroom cost estimate is ~$15K depending on options and a lot of DIY (except the seals).

I haven't decided whether to go with a curved or slanted roof.

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/2_zpsn99jog1q.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/2_zpsn99jog1q.png" border="0" alt=" photo 2_zpsn99jog1q.png"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/3_zps9ua2filj.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/3_zps9ua2filj.png" border="0" alt=" photo 3_zps9ua2filj.png"/></a>

The roof extends a couple of feet over the tank room too.
 
The floor needs to slant slightly towards the outside (like a garage) and I would like a floor drain installed between the DT and the outside edge
 
Ok. Here's the rest of space needed:

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/4_zpslbbygrb6.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/4_zpslbbygrb6.png" border="0" alt=" photo 4_zpslbbygrb6.png"/></a>

The tank actually rests in both rooms - partially in the tank room and partially in the display room

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/5_zpsetks6apl.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/5_zpsetks6apl.png" border="0" alt=" photo 5_zpsetks6apl.png"/></a>

Overall, the design needs about 1250 sqft, even though the display room (and the associated sunroom air conditioning need) is only about 300 sqft.
 
ok - with the site set, here's the build details.

some of this looks convoluted, but it's the result of balancing competing specifications desired.

First, the base

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/6_zpspa73mv9h.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/6_zpspa73mv9h.png" border="0" alt=" photo 6_zpspa73mv9h.png"/></a>

these are 2x4 or 2x6 studs. The skin is 3/4" plywood:

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/7_zps7ifzzxci.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/7_zps7ifzzxci.png" border="0" alt=" photo 7_zps7ifzzxci.png"/></a>

that covers the deep end bottom and separates the display room from the tank room under the stand.

the top is made of multiple sheets of 3/4" plywood

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/8_zpsexcupxlg.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/8_zpsexcupxlg.png" border="0" alt=" photo 8_zpsexcupxlg.png"/></a>

and yes, the tank extends a little beyond the edge in one corner but I think it's manageable.

There's a layer of 3/4" foam on top

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/9_zpsuesckosy.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/9_zpsuesckosy.png" border="0" alt=" photo 9_zpsuesckosy.png"/></a>

Here's the tank "skin" - unfilled.

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/10_zpsrkczesud.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/10_zpsrkczesud.png" border="0" alt=" photo 10_zpsrkczesud.png"/></a>

Next is the internal glass "skeleton" of the tank.

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/11_zpskydpx6sd.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/11_zpskydpx6sd.png" border="0" alt=" photo 11_zpskydpx6sd.png"/></a>

These two internal "false walls" with windows are the ends of display region and the bottom Eurobrace goes against the exposed bottom range holding the base and walls with a large internal separator.

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/105_zpsxiw7fllo.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/105_zpsxiw7fllo.png" border="0" alt=" photo 105_zpsxiw7fllo.png"/></a>

and a large "false floor" completes the cave network:

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/106_zps99b86xwb.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/106_zps99b86xwb.png" border="0" alt=" photo 106_zps99b86xwb.png"/></a>

with a second layer of Eurobrace again holding the sides and second bottom together.

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/107_zps6c3ecfis.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/107_zps6c3ecfis.png" border="0" alt=" photo 107_zps6c3ecfis.png"/></a>

On top of this is the overflow structure and the display tank separator

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/108_zpsmiplucwf.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/108_zpsmiplucwf.png" border="0" alt=" photo 108_zpsmiplucwf.png"/></a>
 
so finally, the tank structure looks like this:

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/109_zpsuyorjxfe.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/109_zpsuyorjxfe.png" border="0" alt=" photo 109_zpsuyorjxfe.png"/></a>

There are two open spaces. One is underneath the "false floor" and the second is at the back end against the back "false wall". The space underneath is a cavern where fish can go.

The space behind the false wall is where the "flowtanks" go. I'll share more about the flowtanks in a bit.
 
ok - flowtanks. These are controlled acrylic boxes that seat inside the back cavity of the display tank. They're accessible from the tank room only (not the display room).

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/20_zps1f6lqsrs.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/20_zps1f6lqsrs.png" border="0" alt=" photo 20_zps1f6lqsrs.png"/></a>

It's basically a large removable box that holds powerheads in a controlled configuration. The powerheads sit in a matrix of eggcrate.

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/21_zpsln4qxrff.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/21_zpsln4qxrff.png" border="0" alt=" photo 21_zpsln4qxrff.png"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/22_zpsjflsh0kj.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/22_zpsjflsh0kj.png" border="0" alt=" photo 22_zpsjflsh0kj.png"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/23_zpspfkjub29.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/23_zpspfkjub29.png" border="0" alt=" photo 23_zpspfkjub29.png"/></a>

and the front has double stacks of eggcrate to reduce attempts by life to impregnate the space.

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/24_zpsmsh61fue.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/24_zpsmsh61fue.png" border="0" alt=" photo 24_zpsmsh61fue.png"/></a>

The eggcrate also laminarizes the flow.
 
When resting inside the DT, the flowtanks structure looks like this:

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/25_zpschvepcpz.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/25_zpschvepcpz.png" border="0" alt=" photo 25_zpschvepcpz.png"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/26_zpsgthysdrm.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/26_zpsgthysdrm.png" border="0" alt=" photo 26_zpsgthysdrm.png"/></a>

so with the eurobracing and all other components, the system looks like this:

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/27_zpshvy9hadc.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/27_zpshvy9hadc.png" border="0" alt=" photo 27_zpshvy9hadc.png"/></a>
 
I also use eggcrate to create the mechanical outlay of the rockscape

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/28_zpsss7okb55.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/28_zpsss7okb55.png" border="0" alt=" photo 28_zpsss7okb55.png"/></a>

and I decided to add a three way wavebox at the end of the peninsula. It's removable in case I don't like it, but it adds another element of flow.

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/29_zpsbtghhy5v.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/29_zpsbtghhy5v.png" border="0" alt=" photo 29_zpsbtghhy5v.png"/></a>
 
the large external circulation loop looks like this:

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/30_zpsqr0j4h74.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/30_zpsqr0j4h74.png" border="0" alt=" photo 30_zpsqr0j4h74.png"/></a>

and here are the pipes alone to make it easier to understand

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/31_zpsm6id9onv.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/31_zpsm6id9onv.png" border="0" alt=" photo 31_zpsm6id9onv.png"/></a>
 
white pipes are drains from the DT to the sump.
red pipes are emergency overflows (into the sump in this case).
green pipes are returns from the surge refugium (above the tank).

There's another network that goes from the sump to the surge, but I'll cover that later.
Finally, I add plywood doors to be able to access under the tank (storage) and to look inside the cavern region (usually dark). Here's the total design so far

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/32_zpsgek1g59w.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/32_zpsgek1g59w.png" border="0" alt=" photo 32_zpsgek1g59w.png"/></a>
 
Thanks guys.

Ok - so a little philosophy about the tank.

You might ask why I have almost half the tank in darkness and why the actual reef is an even smaller ratio of the total water volume. The sump, surge, ATS and other systems are probably another 500 gallons (better math soon).

So.. why?

I believe that natural reefs are composed of many zones and we're only interested in watching the pretty colorful sections. But the hidden sections are just as important as the visible sections.

So I wanted to combine three zones in one tank:

1. The shallow bright reef
2. The deep dropoff reef
3. The dark cave reef

This configuration achieves that.

Next, these zones can easily create many dead zones and I'm personally a big fan of large gyre circulating flow. This is where the four windows come in. The two top windows and two bottom windows as well as the long direction separators in the vertical and horizontal directions really create 4 long paths and the powerheads in the back flowtank can be timed and driven to create circulating flow across any of the four flow zones.

So - three light zones and four flow zones.
 
Here are the light zones:

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/0_zpsgoxmgpax.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/0_zpsgoxmgpax.png" border="0" alt=" photo 0_zpsgoxmgpax.png"/></a>

and here are the flow zones:

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/1_zpsarmaaamy.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/1_zpsarmaaamy.png" border="0" alt=" photo 1_zpsarmaaamy.png"/></a>
 
So, depending on the configuration of pumps, different flow modes are possible. For example:

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/1010_zpsbphvrokx.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/1010_zpsbphvrokx.png" border="0" alt=" photo 1010_zpsbphvrokx.png"/></a>

or

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/0101_zpspsysl0su.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/0101_zpspsysl0su.png" border="0" alt=" photo 0101_zpspsysl0su.png"/></a>

or

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/0011_zpsycxnq3pu.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/0011_zpsycxnq3pu.png" border="0" alt=" photo 0011_zpsycxnq3pu.png"/></a>
 
So there are 16 possible flow modes (really 14 since 0000 isn't a flow mode and 1111 can't really function since there'd be no sink to the sources.)

<a href="http://s1062.photobucket.com/user/karimwassef/media/1_zpshrieaumz.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/1_zpshrieaumz.png" border="0" alt=" photo 1_zpshrieaumz.png"/></a>

Here are the 6 normal modes

<a href="http://s1062.photobucket.com/user/karimwassef/media/2_zpssq8oav5e.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/2_zpssq8oav5e.png" border="0" alt=" photo 2_zpssq8oav5e.png"/></a>

and here are the 4 extreme modes

<a href="http://s1062.photobucket.com/user/karimwassef/media/4_zpswkpwplqg.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/4_zpswkpwplqg.png" border="0" alt=" photo 4_zpswkpwplqg.png"/></a>

and here the 4 gentle modes

<a href="http://s1062.photobucket.com/user/karimwassef/media/3_zpsgdfak5dd.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/3_zpsgdfak5dd.png" border="0" alt=" photo 3_zpsgdfak5dd.png"/></a>
 
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