GSI PNEG-1070 User Manual

PNEG-1070

15', 18', 21', 24', 27' and 30' Diameter Commercial Hopper Tanks

Installation Manual

PNEG-1070

Version: 2.0 Date: 11-29-11

All information, illustrations, photos and specifications in this manual are based on the latest information available at the time of publication. The right is reserve d to make changes at any time without notice.

2 PNEG-1070 15', 18', 21', 24', 27' and 30' CHT’s

Table of Contents

Chapter 1 Introduction ..........................................................................................................................................5

Chapter 2 Safety .....................................................................................................................................................6

Safety Guidelines .................................................................................................................................. 6

General Safety Statement ..................................................................................................................... 7

Safety Instructions ..................... ... .... .......................................... ... ... ..................................................... 8

Safety Sign-Off Sheet ......................................................................................................................... 10

Proper Storage of Grain Bin/Silo Materials Prior to Construction ....................................................... 11

Chapter 3 Decals ..................................................................................................................................................12

Chapter 4 Foundation ..........................................................................................................................................16

12' Diameter Commercial Hopper Tank Foundation up to 12 Rings ................................................... 16

12' Diameter Commercial Hopper Tank Foundation for 13-17 Rings ................................................. 17

15' Diameter Commercial Hopper Tank Foundation up to 12 Rings ................................................... 18

15' Diameter Commercial Hopper Tank Foundation for 13-17 Rings ................................................. 19

18' Diameter Commercial Hopper Tank Foundation up to 12 Rings ................................................... 20

18' Diameter Commercial Hopper Tank Foundation for 13-19 Rings ................................................. 21

21' Diameter Commercial Hopper Tank Foundation up to 12 Rings ................................................... 22

21' Diameter Commercial Hopper Tank Foundation for 13-19 Rings ................................................. 23

24' Diameter Commercial Hopper Tank Foundation up to 12 Rings ................................................... 24

24' Diameter Commercial Hopper Tank Foundation for 13-19 Rings ................................................. 25

27' Diameter Commercial Hopper Tank Foundation up to 12 Rings ................................................... 26

27' Diameter Commercial Hopper Tank Foundation for 13-19 Rings ................................................. 27

30' Diameter Commercial Hopper Tank Foundation up to 12 Rings ................................................... 28

30' Diameter Commercial Hopper Tank Foundation for 13-19 Rings ................................................. 29

CHT Column Heights ... ... .... ... ... ... .... ... ... .......................................... ... ... ............................................. 30

Substructure Parts .............................................. ... ... .... ... ... ... .......................................... ................... 31

Typical NCHT Column ........................................................................................................................ 32

Chapter 5 15'-24' Hopper Assembly ...................................................................................................................33

Hopper Section Assembly 15'-24' (4.57 m-7.32 m) Diameter Hopper Tanks ..................................... 33

18'-21' (5.49 m-6.40 m) 60° “X” Bracing Detail ............................................. ...................................... 38

Chapter 6 27'-30' Hopper Assembly ...................................................................................................................39

Hopper Section Assembly 27'-30' (8.23 m-9.14 m) Diameter Hopper Tanks ..................................... 39

Chapter 7 Sidewall Assembly .............................................................................................................................43

Sidewall Erection Instructions ... ... .......................................... .... ... ... ... ... .... ... ... ... ................................ 43

Decal Sheet Placement ....................................................................................................................... 43

Chapter 8 Lifting Jack .........................................................................................................................................44

Lifting Jack Usage .................................. ... ... .... ... ... ... .......................................... .... ... ... ...................... 44

Color Code Chart ................................................................................................................................ 45

Chapter 9 Hardware .............................................................................................................................................46

Identifying Bolt Grades ........................... ... ... .... ... .......................................... ... ... .... ............................ 46

Hardware Identification Notes ....................................... .......................................... ............................ 47

2.66" Commercial Tank Bolting Requirements 2 Stiffeners per Sidewall Sheet ................................. 51

Caulking Detail .................................................................................................................................... 52

PNEG-1070 15', 18', 21', 24', 27' and 30' CHT’s 3

Table of Contents

Chapter 10 Stiffeners ...........................................................................................................................................53

Commercial Stiffeners for 2.66" Corrugation ..................................................................................... 54

2.66'' Corrugation Commercial Stiffener Splice Details ..................................................................... 55

10 Gauge and 11 Gauge Stiffener Bearing Splice ............................................................................ 57

5 Gauge, 6 Gauge, 8 Gauge and 9 Gauge Stiffener Bearing Splice ................................................. 58

Laminated Stiffener Splice 2.66" Corrugation .................................................................................... 59

Laminated to Universal Stiffener Splice 2.66" Corrugation ................................................................ 61

Stiffener to Sidewall Connections 3 Post Tanks ................................................................................ 62

Non-Laminated Stiffener to Sidewall Detail ....................................................................................... 63

Laminated Stiffener to Sidewall Detail ............................................................................................... 64

Universal Stiffener Starting Location 2.66" Reverse Corrugation Outside Stiffener Only .................. 65

Wind Ring Assembly ......................................................................................................................... 66

Stiffener Shim Plate Detail (Use when Necessary) ........................................................................... 67

Chapter 11 Flashing Instructions (Optional) .....................................................................................................68

Chapter 12 Doors .................................................................................................................................................70

Access Door Weldment Assembly Hardware Package (PLS-41985) ................................................ 70

Chapter 13 Aeration .............................................................................................................................................71

Aeration Package (Optional) ............................................................................................................. 71

Chapter 14 Ladders .............................................................................................................................................74

Ladder Support Detail ........................................................................................................................ 74

Chapter 15 Hoisting .............................................................................................................................................75

Hoist Instructions ............................................................................................................................... 75

Chapter 16 Warranty ............................................................................................................................................79

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1. Introduction

READ THIS MANUAL carefully to learn how to properly use and install equipment. Failure to do so could result in personal injury or equipment damage.

INSPECT the shipment immediately upon arrival. The customer is responsible for ensuring that all quantities are correct. The customer should report and note any damage or shortage on the bill of lading to justify their claim to the transport company.

THIS MANUAL SHOULD BE CONSIDERED a permanent part of your equipment and should be easily accessible when needed.

This warranty provides you the assurance that the company will back its products when defects appear within the warranty period. In some circumstances, the company also provides field improvements, often without charge to the customer, even if the product is out of warranty. Should the equipment be abused, or modified to change its performance beyond the factory specifications, the warranty will become void and field improvements may be denied.

PNEG-1070 15', 18', 21', 24', 27' and 30' CHT’s 5

2. Safety

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

WARNING indicates a hazardous situation which, if not

avoided, could result in death or serious injury.

CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE is used to address practices not related to personal injury.

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Safety Guidelines

This manual contains information that is important for you, the owner/operator, to know and understand. This information relates to protecting personal safety and preventing equipment problems. It is the responsibility of the owner/operator to inform anyone operating or working in the area of this equipment of these safety guidelines. To help you recognize this information, we use the symbols that are defined below. Please read the manual and pay attention to these sections. Failure to read this manual and its safety instructions is a misuse of the equipment and may lead to serious injury or death.

DANGER

WARNING

CAUTION

NOTICE

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2. Safety

This product has sharp edges, which may cause serious injury. T o avoid injury, handle sharp edges with caution and always use proper protective clothing and equipment.

General Safety Statement

Our foremost concern is your safety and the safety of others associated with grain handling equipment. This manual is to help you understand safe operating procedures and some problems that may be encountered by the operator and other personnel.

As owner and/or operator, you are responsible to know what requirements, hazard s, and precautions exist and inform all personnel associated with the equipment or in the area. Safety precautions may be required from the personnel. Avoid any alterations to the equipment, which may produce a very dangerous situation, where SERIOUS INJURY or DEATH may occur.

You should consider the location of the bin site relative to power line locations or electrical transmission equipment. Contact your local power company to review your installation plan or for information concerning required equipment clearance. Clearance of portable equipment that may be taken to the bin site should also be reviewed and considered. Any electrical control equipment in contact with the bin should be properly grounded and installed in accordance with National Electric Code provisions and other local or national codes.

This product is intended for the use of grain storage only. Any other use is a misuse of the product.

Sidewall bundles or sheets must be stored in a safe manner. The safest method of storing sidewall bundles is laying horizontally with the arch of the sheet upward, like a dome. Sidewall sheets stored on edge must be secured so that they cannot fall over and cause injury. Use care when handling and moving sidewall bundles.

Personnel operating or working around equipment should read this manual. This manual must be delivered with equipment to its owner. Failure to read this manual and its safety instructions is a misuse of the equipment.

PNEG-1070 15', 18', 21', 24', 27' and 30' CHT’s 7

2. Safety

Follow Safety Instructions

Carefully read all safety messages in this manual and safety signs on your machine. Keep signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from the manufacturer.

Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.

Keep your machinery in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life.

If you do not understand any part of this manual or need assistance, contact your dealer.

Read and Understand Manual

Practice Safe Maintenance

Understand service procedures before doing work. Keep area clean and dry.

Never lubricate, service, or adjust machine while it is in operation. Keep hands, feet, and clothing away from rotating parts.

Keep all parts in good condition and properly installed. Fix damage immediately . Replace worn or broken p arts. Remove any built-up grease, oil, and debris.

Maintain Equipment and Work Area

Safety Instructions

Our foremost concern is your safety and the safety of others associated with this equipment. We want to keep you as a customer. This manual is to help you understand safe operating procedures and some problems that may be encountered by the operator and other personnel.

As owner and/or operator, it is your responsibility to know what requirements, hazards, and precautions exist, and to inform all personnel associated with the equipment or in the area. Safety precautions may be required from the personnel. Avoid any alterations to the equipment. Such alterations may p roduce a very dangerous situation where SERIOUS INJURY or DEATH may occur.

This equipment shall be installed in accordance with the current installation codes and applicable regulations, which should be carefully followed in all cases. Authorities having jurisdiction should be consulted before installations are made.

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2. Safety

Prepare for Emergencies

Be prepared if fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service,

hospital, and fire department near your telephone.

Keep Emergency Equipment Quickly Accessible

Wear Protective Clothing

Wear close-fitting clothing and safety equipment appropriate to the job.

Remove all jewelry.

Tie long hair up and back.

Wear safety glasses at all times to protect eyes from debris.

Wear gloves to protect your hands from sharp edges on plastic or steel parts.

Wear steel-toed boots to help protect your feet from falling debris. Tuck in any loose or dangling shoestrings.

A respirator may be needed to prevent breathing potentially toxic fumes and dust.

Wear a hard hat to help protect your head.

Wear appropriate fall protection equipment when working at

elevations greater than six feet (6').

Eye Protection

Gloves

Steel-Toed Boots

Respirator

Hard Hat

Fall Protection

PNEG-1070 15', 18', 21', 24', 27' and 30' CHT’s 9

2. Safety

Safety Sign-Off Sheet

As a requirement of O.S.H.A., it is necessary for the employer to train the employee in the safe operating and safety procedures for this auger. This sign-off sheet is provided for your convenience and personal record keeping. All unqualified persons are to stay out of the work area at all times. It is strongly recommended that another qualified person who knows the shut down procedure be in the area in the event of an emergency.

Date Employee Name Supervisor Name

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2. Safety

Proper Storage of Grain Bin/Silo Materials Prior to Construction

Wet storage stain (rust) will develop when closely packed bundles of galvanized material, such as sidewall and roof sheets, have moisture present. Inspect roof and sidewall bundles on arrival for any moisture. If moisture is present, it must not be allowed to remain between the sheets. Separate the sheets or panels immediately and wipe them down. Spray with a light oil or diesel fuel.

If possible, sidewall bundles, roof sheets and other closely packed galvanized materials should be stored in a dry, climate controlled building. If outdoor storage is unavoidable, the materials should be stored so that they are raised above the ground and vegetation. Any stacking and spacing materials should not be corrosive or wet. Be sure to protect materials from the weather, but permit air movement around the bundles if possible.

Storing roof bundles and sidewall sheets at a slight incline can also help minimize the presence of moisture. Storing the bundles with the center of the dome up (like an arch) is one option for minimizing moisture during storage. Sidewall bundles can also be stored on edge but must be secured so that they do not fall over and cause injury.

If “white rust” or “wet storage stain” occurs, contact the manufacturer immediately about ways to minimize the adverse effect upon the galvanized coating.

PNEG-1070 15', 18', 21', 24', 27' and 30' CHT’s 11

3. Decals

The manufacturer does not warrant any roof damage caused by excessive vacuum or internal pressure from fans or other air moving systems. Adequate ventilation and/or “makeup air” devices should be provided for all powered air handling systems. The manufacturer does not reco mmend the use of downward flow systems (suction). Severe roof damage can result from any block age of air passages. Running fans during high humidity/cold weather conditions can cause air exhaust or intake ports to freeze.

CAUTION!

Excessive vacuum (or pressure) may damage roof. Use positive aeration system. Make sure all roof vents are open and unobstructed. Start roof fans when supply fans are started. Do not operate when conditions exist that may cause roof vent icing.

DC-969

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3. Decals

ATTENTION: The decal shown below should be present on the outside of the door cover of the 2 ring,

24" porthole door cover and roof manway cover. If a decal has been damaged or is missing in any of these locations, contact the manufacturer for a free replacement decal.

GSI Decals

1004 E. Illinois St. Assumption, IL. 62510 Phone: 1-217-226-4421

Rotating flighting will

kill or dismember.

Flowing material will

trap and suffocate.

Crusted material will

collapse and suffocate.

Keep clear of all augers. DO NOT ENTER this bin!

If you must enter the bin:

1. Shut off and lock out all power.

2. Use a safety harness and safety line.

3. Station another person outside the bin.

4. Avoid the center of the bin.

5. Wear proper breathing equipment or respirator.

Failure to heed these

warnings will result in

serious injury or death.

DC-GBC-1A

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3. Decals

Failure to heed these warnings

could result in serious injury, death,

structural damage or collapse of tank.

1. Use CENTER FLOOR OUTLET ONLY until NO grain remains above this outlet.

2. Side floor outlets to be used ONLY when above condition is satisfied.

3. Lock all side floor outlets to avoid accidental premature use.

4. See manufacturers instructions for proper use of factory supplied sidedraw (wall) discharge systems.

UNLOADING INSTRUCTIONS:

DC-GBC-2A

WARNIN

DON’T

ATTENTION: The decal shown below should be present on the outside of the door cover of the 2 ring,

24" porthole door cover and roof manway cover. If a decal has been damaged or is missing in any of these locations, contact the manufacturer for a free replacement decal.

GSI Decals

1004 E. Illinois St. Assumption, IL. 62510 Phone: 1-217-226-4421

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